DRILLING FLUIDS

AWARENESS CAMPAIGN

The lifeblood of your well

BASIS OF DESIGN
 Drilling Fluids Awareness Workshop
Basis of Design

Mission Statement

Raise the level of awareness and competency of

Saudi Aramco Drilling Engineers, Rig Foremen and
Mud Engineers for the application of drilling and
completion fluids technologies to meet our drilling
and completion objectives

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design

Workshop Series Structure

Module I Basis of Design

Drill-in and
Module II Completion Fluids

Planning and Logistics

Module III Lessons Learned &
Best Practices

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design

How to get the most out of this workshop

Mobil phones on silent
Active Participation ask questions
Return from breaks on time
Take workbook back to your office / rig
Use it!
Share what you have learned
When in doubt, call your DTD rep

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design

Definition: Set of conditions, needs and requirements taken

into account in designing a mud program.

What do we need to do?

Identify needs and requirements
Identify drilling problems and technical limits (Offsets)
Select the right Drilling Fluid
Preparing the Resources and Contingencies

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Example BOD Field Specific
Drilling Fluids - Design Criteria
Development Wells
Hole Assumptions and Potential Risks/Technical Key Performance
Well Schematic Size
Objectives
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
30" Neogene
Gel slips KARN 2 - 100% losses at 830 ft
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
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 fluid 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

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

18 5/8" Csg

6449' MD/6445' TVD

Have enough LCM material on
Casing point planned at 30 TVD location, particulate and cross link
KARN 6 - Partial losses at 6964 ft
Drill to the kick off point at 6604 ft into base Jilh Dolomite Possible lost circulation in polymers. Be ready to pump cement Bbls mud lost/ft
KARN 7 - Well flowed at 9100 ft
Hold 52 degrees of inclination to DST data from KARN 1 Hanifa plugs LSND Non Productive time
16" Hole KARN 1 - Lost Returns with 77 PCF at
TD (10672 ft) indicated EMW of 69.7 PCF to Possible gas in Jilh Dolomite Keep the planned density at all times allocated to mud losses
6576 ft
balance Manifa and monitor mud pit levels closely
13 3/8" Csg for 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 Control fluid rheology when weighting
KARN 7 - No major problems observed
12898' MD/11115' TVD regardless of high Jilh pressure across Kilh, Sudair and Khuff
Lost circulation in Khuff Use lowest practical MW
Minimize ECD by using low pump KARN 6 - Drilling at 10908 ft, well flowed
Hold 52 degrees inclination to TD. Vibration data can be used in reservoirs Bbls of mud lost/ft
with 95 PCF
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 NPT allocated to stuck
KARN 7 - Stuck at 13935 ft while
problems performance Possible tigh hole/sticking in 250 gpm pipe
Monitor pressure closely while reaming
Khuff formations
15500' MD/12704' TVD drilling

June July 2009

 BASIS OF DESIGN

Saudi Aramco
Typical Mud Systems
(page 3-15)
 GENERAL DRILLING FLUIDS PRACTICES

Drilling fluids are classified by the type of base fluid

used : water or oil.

Different drilling fluids are selected based on technical

and environmental requirements to achieve the required
objectives of the well/project.

Finally, drilling fluid selection and design is optimize for

cost. project.

SAP Training and Change Management

 DRILLING FLUIDS CLASSIFICATION

Drilling Fluids More than 75% of wells

drilled used WBM
in Saudi Aramco
OBM WBM

All Oil Invert Direct Polymer-Based Clay-Based

Emulsion Emulsion

Brine based Drill Water Dispersed Non-Dispersed

Based

SAP Training and Change Management

 WATER-BASED DRILLING FLUIDS

KCl

SAP Training and Change Management

 OIL-BASED DRILLING FLUIDS

SAP Training and Change Management

 TYPICAL MUD SELECTION CRITERIA ONSHORE
e.g. Manifa ERD Wells Onshore

22 Hole Section Spud Mud

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

6-1/8 Hole Section
DIF

SAP Training and Change Management

 DIRECT OIL-IN-WATER EMULSION

DIRECT OIL-IN-WATER EMULSION

Oil emulsified in water

Utilizing simple oil-in-water emulsifier
Oil volume percentage up to 45%
Fluid density can be as low as 56 - 58 pcf.
Minimize potential losses across typically Weak formations in Wasia and
Shuaiba by getting lower densities.

ALL OIL SYSTEM

Designed to protect the Reservoir

Ensures proper reservoir rock protection especially for horizontal drain
holes in clastic reservoirs.
Fluid density can be as low as 56 pcf and can be increased with sized
calcium carbonate or barite for non-payzone drilling.

SAP Training and Change Management

 RESERVOIR DIF OBJECTIVES
Protect the reservoir from formation damage

Bridging the pore throats/fractures

Low residue mud additives
Acid soluble mud additives

Build an external filter cake with low lift off pressure for
complete clean up.

SAP Training and Change Management

 RESERVOIR DIF DESIGN

Particle Size distribution must be matched to the size of the

porosity
For unknown pore diameters use the square root of the
permeability (md) to estimate pore throat size in microns
Base fluid selection is driven by mud weight requirements
and formation sensitivity
Mud additives are selected for premium performance and
minimum damage for the wellbore conditions
For water/brine base fluids, base fluid should be the same as
the completion fluid (this is also true in many cases for oil
base DIF)

Rule of thumb: Minimum solids content

is a design criteria
SAP Training and Change Management
 Reservoir Drill-In-Fluid (DIF)- ALL AREAS
THE COMPLETION STARTS WHEN THE BIT HITS THE RESERVOIR.

WB Reservoir Drill In Fluid BRINE: Brines are aqueous solution at

any concentration of any combination
Water of typical salts generally used to
achieve solids free density or shale
inhibition (can be single salt, 2 salt or 3
XC Polymer salt fluids)

SALT: it is not just as sodium chloride

Modified Starch
(NaCl), but as any type of salt used to
90 94%
BRINE build drilling or completion fluids.
NaOH or MgO
There are 2 classes of salts commonly
used in our industry:
NaCl or other salt
1) Inorganic salt Sodium, potassium,
calcium, or ammonium chloride;
Sized CaCO3
blend sodium, calcium or zinc bromide
2) Organic salt Sodium, potassium or
cesium formate;

SAP Training and Change Management

 Reservoir Drill-In-Fluid (DIF)- ALL AREAS
THE COMPLETION STARTS WHEN THE BIT HITS THE RESERVOIR.

Oil Base Reservoir Drill In Fluid

Mineral Oil
Primary Emulsifier
Secondary Emulsifier
Organophilic clay
Organophilic lignite
Lime
CaCl2
CaCO3 f
Water

SAP Training and Change Management

 RESERVOIR DIF SYSTEM MAINTENANCE

Maintaining particle size distribution and fluid loss properties is the main
objective
Solids control equipment
Proper measurement equipment (PPA, etc)
Regular bridging solids additions

Do not use asphaltic products (Soltex, Blacknite, etc.) in the reservoir and
avoid or minimize bentonite or barite is possible in the mud.
Avoid typical grease pills containing diesel, mineral oil, bentonite, and
barite in the reservoir. Glycol pills are preferred first steps in freeing the
pipe along with reducing mud weight if possible to minimize formation
damage.

THE KEY TO GOOD DRILL IN FLUID AND MINIMUM FORMATION

DAMAGE IS
GOOD WELLSITE MUD ENGINEERING.

SAP Training and Change Management

 A note about brine drilling fluids

Different brines for different densities

Brine compatibilities
Monovalent vs Divalent
Completion fluid must match the drilling fluid
Do not forget crystallization temperature

SAP Training and Change Management

 OVERBALANCE DRILLING FLUIDS

Prevent Differential Sticking of Drill

String.
Key method is creation of tight filter
cake and minimize fluid loss.

How much differential pressure

is high overbalance? It depends
on permeability, inclination, etc.
etc.
Generally speaking, normal mud
can handle up to 500 psi without
special efforts.

SAP Training and Change Management

 OVERBALANCE DRILLING
DIFFERENTIAL STICKING PREVENTION MECHANISM

Utilizing mud pressure

isolation technique.
Create an ultra-low
permeable, finely packed and
slick filter cake across zones
of different pressure regimes.
An overbalanced drilling
fluid can also be designed for
drilling in the reservoir the
additives will be different.

SAP Training and Change Management

 High Performance Water-Based Mud Technology

New alternative to oil based fluids for environmental

reasons.

Strictly targeted at environmentally sensitive areas.

The best system is still an oil-based drilling fluid.

SAP Training and Change Management

 5-STEP PATH TO SUCESS

1. Planning
2. Planning
3. Planning
4. Execution
5. Post well audit/lessons
learned

Mud represents 5 - 15 % of drilling costs but can

cause 100% of drilling problems

SAP Training and Change Management

 Drilling Fluids Awareness Workshop
Basis of Design

Risk Assessment, Contingencies and Mitigations

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Identified Wellbore Risks

Aquifers HP Water Flow

Lost Circulation Hard, abrasive Sandstone

Unstable Hole, Caving Sour Gas

Swelling Shales Reactive Shales

Hard Anhydrites Oil Flows

Tectonics, Bit Sticking Gas

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Identified Wellbore Risks By Formation Type
Sandstone Mud losses
Differential Sticking
Tight Hole
Formation fluid influx (Kick)

Shale Bit balling

Wellbore Instability
Torque & drag
Tight Hole

Carbonates Severe Mud Losses

Differential Sticking
Formation Fluid Influx (Kick)

Anhydrite Mud Contamination

Low ROPs

Siltstone Low ROP

Tight Hole

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design

Drilling Problems related to drilling fluids

Bit Balling

Mud Losses

Hole Cleaning

Wellbore Stability

Stuck Pipe

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling Problems Mud Losses

Prevention Identification Curing

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling Problems Mud Losses
Prevention

Set casing in the LCM Pre-treatment Minimize Downhole

right place pressure
Background
Cover high Cuttings load in the
concentration
pressure zones annulus
Hourly additions
Cover unstable Mud rheology
As pills
zones Surge pressures
BHA limitations
Set it in competent ECD management
Screen selection
formations

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling Problems Mud Losses
Identification & Curing

Locate the loss Zone

Formation
Operational Information Logging Methods
Information

Identify loss mechanism and Assess the severity

Assessing the
Invasion Fracturing
severity

Cure the losses applying the available solutions

Choose LCM recipe as per LCM size and concentration Spotting technique is critical
loss severity assessment will depend on BHA limitations for success

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling Problems Mud Losses
Choosing the LCM

Porous & Fine Fibers

permeable Fine Particles
Fine Flakes
sands

Coarse sands Coarse and Medium fibers,

particles, flakes and marble
and Gravel chips

Cross link polymers

Fractures, Gunk plugs
Vugs, faults, Flash set plugs
Cement plugs
caverns Foam cement

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling Problems Mud Losses
Applying the LCM

Load the active system up to 30-40 ppb with LCM

Direct Check the impact of the LCM on the fluid rheology

and density

Additions Using coarse shaker screens to maintain the LCM

As LCM Concentrations used up to 200 ppb with OEDP

(particles, fiber and flakes)

pills or Cross link polymers, gunk plugs, polymer plugs,

chemical sealants

plugs Cement plugs

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling Problems Mud Losses
Mud Cap Drilling

Do not regain circulation

Use the mud cap to cover

zone of risk at all times

Discontinue use of LCM

Mud cap can be an

inhibitive fluid

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design

Drilling Problems Stuck Pipe

Identification

Mechanical
Hole pack off and bridges
Hole geometry

Differential
Excessive mud weight
Depleted zones

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design

Drilling Problems Stuck Pipe

Prevention

Mechanical Differential

Design well
Minimize
with optimum
overbalance
trajectory

Design BHA
Hole cleaning for minimum
wall contact

Control Control
wellbore filtercake
instability quality

Minimize Keep the pipe

backreaming moving

Monitor Use bridging

torque & drag agents in the
closely mud

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling Problems Stuck pipe
Spotting Fluid - Functions

Attack the filtercake

Create channels through the

filter cake (between DP &
wellbore)

Lubricate (between the DP &

wellbore)

Lower the hydrostatic

Dissolve acid soluble solids,

like CaCO3 (using acids)

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling Problems Stuck pipe
Spotting fluid options

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design

Drilling Problems Stuck pipe

Curing

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling Problems Stuck pipe

The surest way to free stuck pipe is

ALWAYS
BE
P REPARED

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling Problems Stuck pipe
Soaking Time

Question: If you are stuck in the hole, how much time do

you have?
Answer: all day and more!

Spotting pills take time to penetrate the filter cake. Each

pill should be allowed to soak 12 18 hrs
*except surfactant and acid pills
This could mean one pill train is in the hole 36 hrs or
more. Believe it, it works!

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling Fluid Contamination
Typical Drilling Fluid Contaminants or Undesirable Conditions
Carbonates/bicarbonates
Salt
Calcium from cement
Calcium from other sources
Magnesium
H2S
Low Gravity Solids
Air entrapment
Bacterial Degradation
Corrosion
Foaming
Hydrocarbon Influx
Thermal Instability
Emulsion breaking
Water wetting
Iron

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling fluid contamination H2S
Method of Possible effect
Contaminant Compound/ Ion Source Course of action
measurement on fluid
Hydrogen Sulfide H2S / H+, S H2S from formation Garret Gas Train High Yield point Increase Ph > 11
gas, thermal (quantitative). High fluid loss with Ca(OH)2 , or
degradation of Automatic rig H2S Thick filter cake NaOH
organics, bacterial monitor. pH decrease Condition fluid to
action. Lead acetate test pm decrease lower gels for
Ca increase minimum retention
of H2S
Operate degasser

Displace with oil-

base fluid. Add
excess Ca(OH)2 to
precipitate
S=

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling fluid contamination H2S
Pounds SourScav required to remove H2S

20
19
18
17
16
15
14
Pounds per Barrell SourScav

13
12
11
10
9
8
7
6
5
4
3
2
1
0
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000
ppm H2S

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Drilling fluid contamination H2S
Pounds Zinc Oxide Required to Remove H2S

6
Calculation Method:
Conversion Factor to remove H2S with Zinc Oxide =0.000836
H2S amount X 0.00836 X 1.5 = Lbs per Bbl Zinc Oxide Required to remove
5
H2S

*Due to dangers associated with H2S, the treatment level to remove H2S is
4 increased 1.5 times the calculated amount as a minimum to ensure excess
Lbs per Bbl Zinc Oxide

for
total removal.
3

0
0 500 1000 1500 2000 2500 3000 3500 4000
mg/l H2S
Lbs ZnO required to remove

June July 2009

 Solids Control

The Key to Improved Drilling Performance

(Page 107-142)

SAP Training and Change Management

 Solids Classification- see page 110 for details

1) Solids are classed according to their density: Low or High

2) Particles are also classed according to size

API definition
Clay < 2 m
Silt 2 - 74 m
Barite spec. 97% < 74 m
Sand 74 - 1000 m

Solids less than 1 m are 12 times more detrimental to drilling rates than those
greater than 1 m

3) Solids can also be classed according to their chemical reactivity: Reactive or Inert

Generally Speaking, solids are like actors in a movie:

The Good Commercial Solids Solids added to give specific effects e.g. bentonite, polymers,
weighting agents, LCM plus several more.
The Bad Sand Size Solids Drilled Solids produce negative effects & the easiest to remove.
The Ugly Colloidal Size Solids The greatest challenge.

SAP Training and Change Management

 Drill Solids
Size does matter
Assume that a 1 square
DRILL SOLID is allowed to
be re-circulated.
Surface area = ?? sq. in.
There are 6 faces exposed to
the fluid. 1 inch

SAP Training and Change Management

 SOON YOU WILL HAVE THIS
IF NOTHING IS DONE!

Every time a solid is re-circulated, it will get

smaller and smaller and smaller!

SAP Training and Change Management

 Solids Control
THE SINGLE MOST IMPORTANT DRILLING FLUID ISSUE AFTER
DESIGN, IS SOLIDS CONTROL !!

The efficiency of solids control equipment at removing unwanted

solids is at best ~75%
This means 25% of solids are re-circulated and ground down

Reduced Excess
ROP Wear to the
Pumps

Excess Downhole
Drag & Tool Failure
Torque

Increased Excess
Viscosity abrasion

Stuck Pipe Rig

Downtime

SAP Training and Change Management

 Solids Control
OPTIONS FOR CONTROLLING SOLIDS
Dump and Dilute. Effective but very expensive. Usually a part of a
solids control plan.
High efficiency solids control equipment. Remove LGS without
excessive loss of HGS
Inhibitive Drilling Fluid. Reduces dispersion of solids and
improves efficiency of solids control equipment.
Efficient solids control reduces costs
Lower dilution rates
Less mud treatment

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.

SAP Training and Change Management

 How To Evaluate Solids Content Of
Mud? Sample Source
MUD PROPERTIES
Flow Line

Time
Flow Line Temp.
Depth
F
ft
1:58
160
5,430.00

It requires proper mud analysis at Mud Weight

Mud Gradient
Funnel Viscosity
lb/ft3
psi/ft
sec/Qrt
83.00
0.58
73
location and calculation of the different 600 RPM
300 RPM
99
61
solids components. 200 RPM
100 RPM
47
30
6 RPM 10
The best way is to rely on experience, 3 RPM
Rheology Temp. F
8
120
PV cP 38
refer to prepared rule of thumb graphs or YP lb/100ft2 23
LSYP lb/100ft2 6
require a competent mud engineer with Gel Strength(10s) lb/100ft2 11
17
Gel Strength(10m) lb/100ft2
computer software to produce the API Fluid Loss
HTHP Filtrate
ml/30min
ml/30min 2
numbers. Cake API/HTHP
Sand Content
1/32nd in
Vol %
1

Retort Oil 52
A solids analysis for the mud in use is Retort Water
Retort Solids
23
25
Alkalinity Mud (Pom) 4
reported on the Daily Mud Report. Excess Lime ppb 6
Emulsion Stability V 950
Oil Water Ratio 69/31
Cl- mg/l 310 k
BIT HYDRAULICS SOLIDS ANALYSIS
AV / DP ft/min 134.98 CaCl2 Vol % 3.63
AV / DC ft/min 200.01 CaCl2 % wt 36.2
AV / RISER ft/min CaCl2 mg/l 488,763
na / ka 0.3771 / 4.6151
Av.sp.Gr.Solids 2.62
np / kp 0.6982 / 0.8369
Corrected SolidsVol % 21.37
BIT HHSI hp/in2 0.97 Avg. Sp. Gr. of Salt Water 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

SAP Training and Change Management

 How To Evaluate Solids Content Of
Mud?
Solids Content Definitions
Retort Solids Represents the total solids in the mud as read directly
from the retort tube and includes soluble solids (salt).
Corrected Solids Represents the total solids in the mud MINUS the
soluble solids (salt).
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).
Drill Solids Represents the total solids in the mud MINUS soluble salt,
any weight material and chemical additives.

Rule of Thumb: Low Gravity Solids = 5 8% for a barite mud. 3 4%

for a reservoir drill in fluid

SAP Training and Change Management

 How To Evaluate Solids Content Of
Mud? Suggested Tools
Recommended Solids Charts:
Target Solids Percent for Muds that Don't Contain Barite- page 112
Mud Weight versus Total Solids % for OBM with No Drill Soldis-CaCO3
as a weighting material- page 113
Density of Water & Diesel Emulsion with 3% LGS- page 114
Solids Content versus Mud Density (Barite & Hematite)- page 115
Recommend Trend Charts page 116
A simple tool to check on DIH and find similar muds to see how mud
solids compares to other wells- page 117

SAP Training and Change Management

 Solids Control Equipment

Function
Reduce overall well costs through the efficient removal of drilled
solids while reducing and minimizing the loss of drill fluids.
Strategy
The design objective of any SCE is removal of progressively finer
drilled solids.
Types
Shale Shakers (vibrating screens)
Settling Pits (sand traps)
Large hydrocyclones >8 in diam. (desanders)
Smaller hydrocyclones <6 in diam. (desilters)
Mud cleaners (desilters with fine screens
underneath)
Centrifuges

SAP Training and Change Management

 Solids Control Equipment

When to run SCE and what equipment to run? (pg 119)

Shakers: ALL SHAKERS ALL THE TIME. There is no such thing

as a spare shaker.
Screen Coverage by the mud pool at 75 80%
Hydrocyclones: Spud mud only, any other time is throwing away
good drilling fluid and grinding solids
Mud Cleaners: their only value is another shaker screen, do not
use the hydrocyclones
Centrifuges: when in use, run almost continuously (even after
achieving the target mud properties pg 134)

SAP Training and Change Management

 Shale Shakers
Most important solids removal equipment on rig.
Cheapest way to remove drill solids.
Only equipment that actually removes solids by particle size.
Process entire circulating volume
Screen Selection is a Compromise Between:
Amount of solids to be removed
Circulation rate
Screen life expectancy

Flowrate across a shaker is dependant on:

Cuttings loading of the mud (ROP)
Mud temperature
Shaker design
Mesh type and size

SAP Training and Change Management

 Shale Shakers- 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.
Best practices must be tailored to specific conditions
Minor mud losses over the screen are acceptable and often beneficial.
Have your shakers checked by a vendor representative on a regular
basis.
Shale shakers should be inspected regularly:
Screen wear
Flow handling
Cuttings transport
Increase in flowline mud weight can be due to:
Worn screens
Incorrectly fitted screens

SAP Training and Change Management

 Sandtraps

Sand traps are essentially settlement tanks.

Normally located directly beneath the shale shakers.
Should be fitted with baffles to increase flowpath.
Usually a minimum of 2 tanks.
With WBM, good practice is to dump the contents
when performing whole mud dilutions or on trips.

SAP Training and Change Management

 Centrifuges
Modes of operation
Reduce Mud Weight - (1 or 2 Centrifuges - discharge barite)
High feed/low speed to maximise mud weight reduction

Total Solids Removal Mode (1 or 2 Centrifuges Reduce drill

solids and viscosity/PV)
Total solids removal (as much as possible)
Low feed/high speed to remove all solids

Dual Stage Mode ( 2 Centrifuges Reclaim barite and base fluid /

discharge drill solids)
Centrifuges work in tandem
1st centrifuge run as high feed/low speed to separate coarse barite
which is returned to the active system. Liquid discharges to a
holding tank.
2nd centrifuge fed from holding tank. Run as low feed/high speed to
separate fine solids which are discharged. Liquid returns to active
system.

Note: Centrifuges do not process the entire

circulating volume (10-15% of total)
SAP Training and Change Management
 Without a Centrifuge and Using Typical SCE, Finer
Solids are left in the system

20 x 4 Desilter

3 x 10 Desander
Typical %age

Solids remaining Mudcleaner(s)

in the mud system
150 Mesh
3ea. Linear Motion shale shakers

0 508 5128 201230044 3074

44 74150105 250 150
105 400 250 400900600900
600
Particles Remaining in the Mud (microns)

SAP Training and Change Management

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

Dual RT 362 HeviJet

centrifuge

Triple VSM 300

Balanced Elliptical
Typical %age

Shale Shakers

Removing this amount 200 mesh

of additional solids
from the current system

0 5 8 12 20 30 44 74 105 150 250 400 600 900

Particles Remaining in the Mud (microns)

SAP Training and Change Management

 RECOMMENDATIONS

Mud Cleaners were introduced in the 1980s to remove finer solids

Technology has moved forward and shaker performance has improved to such a
level that Mud cleaners are not normally used
The only equipment that will removed fine & Ultra fine solids from the mud after
being processed by the shakers is a High Speed Centrifuge
The Optimum System consists of:
An adequate number of shakers to handle the full circulating volume
High efficiency centrifuges to control fine solids and to facilitate barite
recovery

A typical may include hydrocyclones. These must ONLY be used when

absolutely necessary

SAP Training and Change Management

 Drilling Fluids Awareness Workshop
Basis of Design
Health/Safety and Environment
H2S Awareness
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

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Health/Safety and Environment
Material Safety Data Sheet Information

Identification of the substance/preparation and the company

Composition/information on ingredients
Hazards Identification
First Aid Measures
Fire fighting measures
Accidental release measures
Handling and storage
Exposure controls and personal protection
Physical and chemical properties
Stability and reactivity
Toxicological information
Ecological information
Disposal consideration
Transport information
Regulatory information

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Health/Safety and Environment
Material Safety Data Sheet Information

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Health/Safety and Environment
Chemical Hazard Bulletins

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Health/Safety and Environment

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
ENVIRONMENTAL GUIDELINES
ENVIRONMENTAL STANDARDS, PROCEDURES AND GIs 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/epd.home.do

Corporate Environmental Protection Policy INT-5 http://epd.aramco.com.sa/epd/epd.home.do
Corporate Environmental Protection Policy Implementation GI- .2.714 http://epd.aramco.com.sa/epd/epd.home.do
EPA Procedures SAEP - 32 http://epd.aramco.com.sa/epd/epd.home.do
Land Use Permit Procedures GI. 2.716 http://epd.aramco.com.sa/epd/epd.home.do
Waste Management This doc provides direction and GI- 430.001 http://epd.aramco.com.sa/epd/epd.home.do
guidance to Company organizations on the proper handling Company Standards
and disposal of wastes. Environmental Protection
Waste Management
Borrow Pit Requirements SAES A- 111 http://epd.aramco.com.sa/epd/epd.home.do
Solid Waste Landfill Standard SAES-S-007 http://epd.aramco.com.sa/epd/epd.home.do
Ambient Air Quality & Source Emission Standard SAES A-102 http://epd.aramco.com.sa/epd/epd.home.do
Processing and Handling of Hazardous Material CU 22.01 http://epd.aramco.com.sa/epd/epd.home.do
Handling Bulk/Non-Bulk Chemicals CU 22.05
Discharge to the Marine Environment SAES-A-103 http://epd.aramco.com.sa/epd/epd.home.do
Discharges from Drilling Operations Clause 4.5, Company Standards
o Guidelines on the discharges of OBM, alternative Sub-Clauses 4.5.1, Wastewater & Marine Protection
OBM and water base drilling fluids and cuttings. 4.5.2, 4.5.3, 4.5.4, Discharges to the Marine Environment
4.5.5.
Offshore Oil Spill Contingency Plan G.I. 2-400 http://epd.aramco.com.sa/epd/epd.home.do
Leak and Spill Reporting-Arabian Gulf G.I. 2.104 Company STandards
Wastewater & Marine Protection
Wastewater Treatment, Reuse and Disposal SAES-A-104 http://epd.aramco.com.sa/epd/epd.home.do
Onshore Wellsite Environmental Management Operations D&WOSD http://eccweb.enp.aramco.com.sa/drilling/NewDIH/DWOSD_web/WebPage/DwosdPro.
Procedure Environmental html
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/epd.home.do
Ionizing Radiation Protection G.I. 150.003 http://epd/epd/epd/contentAction.do?name=COMPANYSTANDARD
Fishing For Radioactive Tools Chapter 5 Section C Drilling Manual
Abandonment Guidelines For Radioactive Tools Chapter 2 Section G Drilling Manual
Sub-section 3.0
Radiation Protection Requirements for Downhole Well Draft
Logging Incidents

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Knowledge Management

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Knowledge Management
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/100ft 11 12 17 18 16 Abandon bbls
Gel 10 min. lb/100ft 13 16 21 20 19 Left in Hole bbls
Gel 30 min. lb/100ft 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/100ft 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 lbs^n/100ft 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 (35) 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:

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Knowledge Management

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design
Knowledge Management

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design

END OF PART I

June July 2009

 Drilling Fluids Awareness Workshop
Basis of Design

Who you gonna call?

DTD Technical Support Services
Drilling Fluids Specialists
Name Assigned Office Cell
Area Phone Phone
Adel Ansari Special 862-8521 050 499 0963
Projects
William Duran Offshore 862-8509 055 450 1094

Darrell Foreman Gas 862-8265 050 054 4962

Jason Hubbard Workover 862-8042 050 385 7903

SADD
Ismaeel Musa Exploration 862-8523 050 305 5263

Moon Ho Seah NADD 862-8306 055 600 1532

June July 2009