Cn TZ) atom DRC ster 3 ro gard La RooShell U.K. Limited This document is the property of Shell U.K. Limited, and the copyright therein is vested in Shell U.K. Limited. All rights reserved. Neither the whole nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the copyright owner. COB Graphic Design & Maine1.0 14 12 13 14 20 24 22 23 24 25 26 27 28 29 2.10 2411 212 2413 3.0 34 3.2 a3 34 35 36 37 38 4.0 Contents Introduction Objectives Clean-up Task Force ‘Well Clean-up Process Flowchart Integrated Clean-up and Debris Management Team Hole Cleaning - Removal of Driling Solids Flow Regimes Annular Velocity Pipe Eccentricity / Annular Flow Profile Hole Inclination / Cuttings Beds Mud Rheology Sweeps Pipe Rotation / Reciprocation Wellbore Geometry Particle Size, Shape and Density Slip Velocity Transport Index Software to Predict Hole Cleaning Effectiveness Hole Cleaning Operations ‘Summary of Hole Cleaning Mud Displacement Circulating and Conditioning Mud Mud Displacement Pills Drillpipe Stand-off (Pipe Eccentricity) Annular Flow Profile Pipe Rotation / Reciprocation Critical Flow Rate Turbulent Flow Displacement ‘Summary of Mud Displacement Chemical and Mechanical Clean-up wepn as 12 13 14 14 14 15 2 24 25 25 26 2B 31 32 33 37HB contents 4.4 Description of Fluids 38 4.1.1 Oily Muds 38 4.1.2 Solvents 38 4.4.3 Surfactants 38 4.4.4 Flocculants 38 4.1.5 Tables of Chemical Products 40 4.2. Description of Mechanical Tools 41 43 Areas for Clean-Up ar 4.3.1. Surface Systems 48 4.3.2 Subsurface Systems 49 4.4 Performance Measurement 49 5.0 Recommended Cased Hole Clean-up Procedures 52 5.1 Well Planning 52 5.4.1. Gathering Data 52 5.1.2 Use of Shell Expro Well Engineering Software. 54 5.1.3 Use of Shell Expro Databases on IVORY Server 55 & Wells Global Network . 5.1.4 Use of Clean-Up Focal Point 56 5.1.5 Summarising 56 5.4.6 Design of Chemical Clean-up Process 87 5.1.7 Guidelines for Chemical Operations 58 5.1.8 Design of Mechanical Clean-up String 59 8.1.9 Generic Clean-up BHA's for Subsea and Platform Scenarios 64 5.2 Prepare Draft Programme 65 6.0 Execution of Cased Hole Clean-Up 66 6.1 Surface Systems 6 62 Subsurface Systems 68 7.0 Reporting and Job Analysis 1m 8.0 Appendices 72Introduction ‘Over the period from late 1997 to the beginning of 1999 Shell Expro's well completion performance, particularly in subsea wells, had deteriorated significantly. The percentage NPT in the completion phase of wells was noted to be typically 2 to 3 times greater than in the driling phase. In the case of some NPT events there was ‘a chain of consequential problems resulting in major “train wreck" incidents. In other cases the consequences were less severe, but always resulted in additional time ‘and cost to rectify the situation - time and cost that could have been saved if the well had been properly cleaned in the first place. EE] Objectives In the absence of any pre-existing guidelines, the Clean-up Task Force have written this booklet “ABC Guide for an Engineering Approach to Cased Hole Clean-up" to serve a8 a training and reference guide that wil provide improved understanding and recommended procedures for better well clean-ups in the future. The Guide identifies that cased hole clean-ups actually consist of three distinct phases: - + Hole cleaning - removal ef riling solids (prior to mud displacement) + Mud displacement * Chemical and mechanical clean-up. The Guide describes the engineering aspects to be considered for the clean-up and recommends "best practices" for equipment selection, chemical agents and operational Procedures that should be applied for each activity ina cased hole clean-up, ie. all 2clvities in the Planning, Execution, Reporting and Leaming phases. Chapters 2 to 4 discuss the underlying Theory whilst Chapters 5 to 7 offer guidelines for the Practice.EE Clean-up Task Force (On 21.7.9 a Clean-up Study Task Force was established. A documented review of the data that was collected, the analysis and evaluation performed, the conclusions drawn from the findings, and the recommendations proposed for those areas identified where improvements can be made, were presented to the project co-sponsors in report entitled "Pre-Completion Well Clean-up Study, WEIN 961", The well clean-up study was executed over the period from 21.7.99 to 31.10.99 by the following team of full and part time members : - TeamLeader J. Simpson UESM/10 (Full time) Team members N. Hamilton UESC/8 (Part time) Glaw UEDN/8 (Part time) N. MacBeath UESP/14 (Part time) M. van de Velden UESM/10 (Part time) B. Simpson. UESM3 (Part time) Well Clean-up Process Flowchart ‘schematic representation of the linkage between onshore and offshore personnel, plus lead contractors and subcontractors needed for an effective clean-up process, has been recorded for reference in a flowchart that is included as Appendix 1.Integrated Clean-up and Debris Management Team ‘The appointment of the Clean-up Focal Point now offers the WDT's expert advice ‘and provision of co-ordination for the well clean-up process. By working with both Well Delivery Teams (WDT's) and service contractors the focus will be to stimulate greater attention to both planning and execution phases of the clean-up program. In addition the Focal Point will offer the following services : - + Maintenance of a database with clean-up programme designs for different well scenarios, + Provision of data collection forms. + Provision of recommendations for standard BHA's. + Provision of recommendations for standard chemical trains (in consultation with Production Chemisiry, UESP), + Standard procedures for each phase of the clean-up. Compilation of statistics of mechanical tool performance and chemical usage. + Maintenance of well clean-up information on the IVORY server. Itis recognised that ultimate responsibilty for well clean-ups lies within the well delivery team for each rig, Itis the WDT's collective responsibilty to design, engineer, plan, programme, execute and report upon the well clean-up activities, Individual elements of the overall process may be delegated to different members of the WOT's, including delegation to contractors and service companies, but the overall responsibilty remains within the line. This integrated process is pictorally represented below :- Integrated Clean-up & Debris Management TeamEJ Hole Cleaning - Removal of Drilling Solids The removal of all driling solids, prior to mud displacement and chemical clean-up, is important for two reasons = 1. The removal of driling solids from a deviated wellbore should be performed when mud, which has good carrying capacity is in the well. Once the mud has been displaced from the wellbore, solids remaining in a highly deviated wellbore will not be lifted out by seawater and high-vis pills. 2. The base fluid and clean-up chemicals will not remove solid debris from the welloore. The clean-up chemicals will dissolve only a thin flm of residual oll that is left on the casing walls. Any significant quantity of solids, gelled mud or cuttings beds remaining in the wellbore will rapidly reduce the effectiveness of the chemicals. (One of the primary functions of driling mud is hole cleaning, Efficient hole cleaning 's diractly dependent on the ability of mud to suspend the dill cuttings and carry them to the surface. Factors affecting the carrying capacity of a driling fluid are :- + Annular velocity. + Pipe eccentricity because of its effect on the annular flow profile. + Hole inclination because of its effect on cuttings beds, ‘ + Mud rheology. + Sweeps. * Pipe rotation and reciprocation to counteract setting tendency. + Wellbore geometry. + Particle size, shape and density, + Slip velocity and transport index. Prior to discussing these factors an overview of flow regimes is presented as the terminology is frequently referred to in this section.Flow Regimes Generally speaking there are two flow regimes of interest in drilling operations: laminar and turbulent. In fluid flow theory there is another regime called plug flow. ‘The particular flow regime of a driling fluid, during driling operations, can have a dramatic effect on pressure losses, hole cleaning and hole stability. oia.0 Lamar oe Ce ameer SE atu a rr a ee =) 3)" S35 | ne 31> ‘Dt 7% ® eae, 4 I Plug Flow Plug flow is @ special type of laminar flow and only occurs with high yield stress fluids moving at low velocities, The central part of the fluid moves as a plug with the same particle velocities and a shearing effect is only present at the pipe wall ‘Asa resul ofthis the velocity profile in plug flow has a flat centre portion. In driling ‘operations, plug flow occurs at iow velocities and when the mud thickness (viscosity) is high. Laminar Flow In laminar flow the flow pattern is smooth and devoid of any disturbances such as eddies, wih fluid layers travelling in straight or gently curving lines parallel to the conduit axis. Hence in this flow regime, there is only one component of fluid velocity ‘and that is longitudinal fo the wellbore. Where liquids such as water or oil wet the pipe surface, the particles in contact with the pipe wall are considered stationary. The velocity of each layer increases towards the middie of the stream until a maximum velocity is attained at the centre. The velocity profile for water, for instance, displays ‘@ parabolic shape in which the particles are stationary at the wall and flow is at twice the average velocity at the centre. Laminar flow is generally associated with low fluid velocities as found in the annulus of a hole, or with highly viscous fluids.Turbulent Flow ‘Turbulent fiow is @ chaotic flow characterised by intense mixing caused by eddies. Hence in this flow regime, the random movement results in two components of velocity and they are longitudinal and transverse to the conduit axis, Despite turbulence, the final velocity profile tends to be a uniform one over the majority of the pipe area, with velocity decreasing rapidly at the pipe wall. This uniform profile results from an enhanced mixing of low and high velocity particles. Even in turbulent flow, particle fluctuation near the conduit wall dies out and the flow pattem in this region is essentially laminar. This region is called the laminar sub- layer and its thickness depends on the degree of turbulence. The relationship between the thickness of the laminar sub-layer and the degree of turbulence is an inverse one. In drilling operations, in open hole, turbulent flow in the annulus is to be avoided since turbulence can cause severe hole erosion. Pressure losses and pumping power requirements also increase with the degree of turbulence. However in cementing operations, turbulence is deliberately initiated to help displace the mud cake from the walls of the hole, thus allowing the cement to contaet the fresh surfaces of the formation resulting in a better cement job. This practice is also initiated in wellbore clean-ups, where @ base ol pills pumped in turbulent flow when displacing an oll based mud from the wel Turbulent flow generally occurs at high velocities and / or at ow fuid viscosities.Annular Velocity Itis the viscous drag produced by shear stresses in the fluid that provides the lifting force to carry cuttings out of the wellbore. These drag forces increase as the annular fiow rate increases. The diagram below illustrates the transmission of shear stresses across Muid layers in the flow stream :- Statenary Layer wih 2er velocty — open Presse rere ey e In highly deviated wells, flow rate is the most critical parameter affecting hole cleaning efficiency. An increase in annular velocity improves hole cleaning, regardless of the flow regime. It is generally recommended that the annular velocity be kept above 2 minimum of 180 fmin The average annular velocity (Va) in a concentric annulus is given by = 24.50 VA" Oh -DpD (min) Where Q = flow rate (gpm) Dh = hole diameter or casing ID (ins) Dp = drilippe OD (ins)Pipe Eccentricity / Annular Flow Profile The best carrying capacity is produced when the drillpioe is concentric within the annulus. This provides a uniform annular profile throughout the annular cross section. In vertical wells the effect of drillpipe eccentricity is small and the eccentricity will be oscillatory in nature during drillpipe rotation. Concentric Diillpipe eccentricity has a large effect in deviated wells, especially horizontal, where the geometry of the drillpipe inside the casing wellbore has a significant effect on the annular flow profile. The laminar flow profile has @ maximum velocity at the centre and a zero velocity at the pipe walls. The turbulent flow profile is fairly flat over the majority of the annular section, Thin fuids in turbulent flow provide superior hole cleaning in high angle wells, where the flatter flow profile ensures that sufficient flow velocity is achieved across the annular area. Although it is easier to induce turbulence in low iscosily fluids, je. water, this is an inferior fluid for particle suspension under static conditions,EB] Hole inclination / Cutting Beds In vertical holes, the annular velocity (Va) must overcome the slip velocity (Vs) in order to lif the particles out of the hole. When the hole inclination @ increases from Zero, the slip velocity will have two components: Vs Cos @ against the flow and Vs Sin @ perpendicular to the flow. For horizontal holes, @ = 90" and Vs Sin @ becomes equal to Vs. From the above, it would appear that the annular fluid will have to ‘overcome the full slip velocity in vertical wells and a smaller slip velocity in deviated ‘wells. Or put simpler, in a vertical hole the flow is straight up with the solids slipping in the opposite direction to the flow. As long as the fluid in the well is flowing faster than the slip velocity of the solids the solids will be carried upwards in the well. If the flow stops the solids will fall down the well. If the flow remains off for a long Period then they may reach the bottom of the well; filing the hole. Solids will always fall vertically, as gravity acts that way. In a high angle well (>65 degrees) or @ horizontal well the solids will rapidly fall to the low side of the hole. Since the axial flow velocity at the side wall is lower than in mid-stream the rate at which the solids are carried out of the well declines and a layer of cuttings may start to accumulate. ‘ |na high angle or horizontal well, the time it takes for the solids to fall to the low side of the hole when the pump is tumed off is dependent upon the gel strenaths of the drilling fluid being used. However the distance the solids have to fallin a highly deviated well is only a few inches. This explains why solids settie out very quickly in a deviated well and why hole cleaning in deviated wells is such a challenge and requires to be recognised and addressed at the well planning stage. The layer of solids lying on the low side of a deviated well is called a cuttings bedThe following has been shown experimentally for varying hole angles Re cr 0-10 Similar to that in a vertical well and there is no tendency for cuttings to form a bed. >10 Radial slip velocity (Vs Sin 2) forces the cuttings towards the {ow side of the annulus resulting inthe formation of a cuttings bed. 40-50 At low flow rates the bed thickness increases with hole angle, reaching a maximum at hole angles within this range. This is | the critical range of hole angles where hole cleaning is more difficult due to the gravity forces causing the cuttings beds to slide downwards against tne flow. With no flow rate the cuttings beds tend to avalanche down the wellbore, which can result | in packing off around dril strings, ‘ 50-90 An equilibrium thickness is reached where the rate of bed formation is equal to the rate of bed erosion. AAs the flow rate is increased, the bed is de-stabilised and more cuttings are forced into the flow stream,The effects of hole inclination will also depend on whether the hole is building, holding ‘or dropping angie. Hole Angie Sere Ker Building Pipe lying against upside of hole, with large flow area on the low-side to aid hole cleaning, Holding or Pipe lying on low-side of hole, with a tendency for particles to Dropping _| fall and form a cuttings bed. Large flow area on the upside of | the hoie. Horizontal | Pipe lying on low-side of hole. No force to cause cuttings to slide backwards and the bed will bud up until annular velocity is high enough to prevent further bed deposition. EZ] Mud Rheology ‘ ‘The relationship between mud theology and hole cleaning varies, depending on the annular flow regime. For laminar flow conditions, in horizontal and high angle wells, w'scesity and gel strength are critical. Viscosity provides the mechanism by which fluid energy is transferred to the cuttings. Gels provide suspension under static Conditions, such as when the flow stops due to the pumps being tured off Another property to consider isthe yield stress (YZ). The YZ is caleulated from the viscometer 3 rpm and 6 rpm readings, using the formula YZ=2x3rpm-6 rpm Note: YZ (vold stress) isnot the same as YP (yelé point) which is calculated using the formula YP = 2x 300 rpm ~ 600 rpm. "‘The YZ gives an indication of the mud's suspension ability under low shear conditions. Typically the YZ should be >= 10. Some mud companies have ultra low shear viscometers, which give a better insight into low shear characteristics of the mud. + Inthe laminar flow regime, the influence of mud rheology on cuttings transport is significantly greater for vertical and low angle wells. + Viscosity does not affect the hole cleaning ability of a mud in turbulent flow, however a low viscosity mud will go into turbulence at a lower pump rate. + Turbulent flow is preferred for hole cleaning, however, laminar flow is effective for hole angles below 45° + Higher mud weights improve hole cleaning by increasing the buoyancy of the drillad cuttings. + Rheologi those required for mud displacement. EB] sweeps Displacement of high-viscosity sweeps to improve cuttings removal is common practice. Hi-vis pills are most effective in vertical and low angle wells, however they be effective in high angle wells if the cuttings can be introduced into the flow stream. Since cuttings normally settle into beds in high angle wells, the bed needs to be disturbed by rotation / reciprocation whilst the hi-vs pill is passing. 3! properties beneficial to hole cleaning are normally the opposite of Turbulent sweeps can help hole cleaning if the flow rate is high and the volume of the swoop is adequate. Turbulence can erode existing cuttings beds. However if the volume of the sweep is insufficient, cuttings will be transported only a short distance before setting back to the low side of the hole. This problem can sometimes be overcome by following a turbulent sweep with a viscous pil 2Pipe Rotation / Reciprocation Jn deviated wells high pipe rotation speeds provide an effective means of mechanically disturbing cuttings beds and re-introducing them into the mud flow stream for removal This is particularly useful in laminar flow, with viscous fluids, so that particles on the low side of the hole are moved into the higher flow velocity regions. While fotation can agitate a bed and move cuttings into the flow stream, particles can settle and be re-deposited quite quickly if viscosity and gel strengths are insufficient. A viscous couple will result between the pipe and mud when the pipe is rotated and. this will be larger if the gel strengths and low shear rate viscosities of the mud are elevated, The diagram below illustrates the effect of pipe rotation :- ———<—— No Rotation Rotation WO GoledMud | + Pipe rotation has a greater impact in larger hole sizes. + Pipe rotation above 60-100 rpm (depending on hole size — see table below) ives no further improvement to the cuttings transport mechanism. + In turbulent flow, the improvement in hole cleaning obtained by drillpige rotation is less than in laminar flow. + Reciprocation of the drillpipe assists in moving cuttings beds and encouraging them into the flow stream, The tool joint upset provides a scraping effect. For ‘maximum benefit the stroke length of reciprocation should at least be equal to the distance between adjacent too! joint upsets.‘The rotary speed for maximum benefit is dependent on hole size as detailed in the table below cap nee eS 12414" 812 é 260 60 EX] Wellbore Geometry Wellbore geometry variations impact on solids removal because they affect the annular velocity and hence the shear rate of the mud. Geometry variations also create ‘traps’ where sliding cuttings can accumulate. Variations are caused by changes in dil string and hole, riser or casing diameter EA Particle Size, Shape and Density Hole cleaning is dependent upon cuttings size, shape and density. In a highly deviated well, cuttings can remain in the high angle section ifthe hole js not being cleaned properly. These cuttings can be ground down, due to the rotation action of the drilpipe, and be deposited on the low side of the hole. Slip Velocity / Transport Index Increases in cutting size and / or density jcrease the cutting slip velocity. This makes transport more difficult. Increasing the yield stress and gel strength of the mud can reduce the effects of a higher slip velocity. The transport index is a measure of the mud’s carrying capacity and it combines the mud weight, a theology factor and wellbore inclination with a length factor. This Index is then related to the circulation required to clean a wellbore. Experience and calculated figures in deviated wells normally indicate that 1.5 to 2.0 times bottoms up, or even more, is required to remove the cuttings in a highly deviated well. 4ERI Software to Predict Hole Cleaning Effectiveness EzClean is a versatile Windows program whose primary purpose is prediction of cuttings transport and associated circulating pressure profiles. Its prime objective Is to enable the well engineer to design fluid properties and driling conditions that wil effectively clean the well while maintaining borehole integrity, Toward this goal, the program provides the user with a suite of results for cuttings concentration and dynamic pressure throughout the well for rotary driling, sliding, and circulating ‘operations. In addition the program calculates @ Hole Cleaning Index (HCI), which can be used as @ measure of the likelihood of drill pipe sticking problems while pulling out of the hole due to cuttings collected in intermediate and high angle sections of the wellbore. The cuttings transport and circulating pressure models within EzClean take into full ‘account fluid rheology and density dependence on temperature and pressure, hole inclination, rate of penetration, drill pipe rotation, drill pipe eccentricity, cuttings size, cuttings density and wellbore geometry. The cuttings transport modelling capabilities of EzClean can provide the following input for engineering well clean-ups (the figures that follow are shown for illustration purposes only) ~ + An overview of the well geometry (inclination versus measured depth), configuration (casing / liner inside diameters, string outside diameter) and anticipated flow regime (laminar / transitional / turbulent). This overview will identify critical sections of the wellbore, which will enable the user to focus on critical hole sections for subsequent engineering work. For example, a liner top in a vertical section of the wellbore will not have the same requirements to clean up as one at 50 degrees, * An overview of the solids concentration versus measured depth, This overview provides an identification of critical sections of the wellbore at which a collection of solids could be expected. 45+ Aprediction ofthe impact of operational parameters on the clean-up effectiveness for each of the critical sections in the wellbore. Parameters that can be studied in the sensitivity analysis are :- + Particle size + Particle density + Flow rate + Fluid density + Fluid rheology + Drill string rotation speed + Dril string configuration (e.g. diameter) + Drill string eccentricity + An evaluation of the most effective methods and their operational requirements to remove solids from the critical sections of the wellbore. + An optimisation analysis of selected clean-up parameters (e.g. flow rate, fluid theology), The pressure modelling capabilities of E2Clean provide the possibilty to analyse clean-up monitoring parameters. When using EzClean to engineer cased hole clean-ups, the following should be noted = * An appropriate methodology can be applied, ie. not just locking at generating turbulent flow. + Ezclean is a Shell product. This provides the advantage of insight into the underlying models and their limitations. + EzClean indicates equilibrium conditions. It does not make predictions about the time (or pumped fluid volume) required to reach those equilibrium conditions. + EzClean has been calibrated in Shell Expro for typical drilling parameters+ The HCI concept to quantify acceptable levels of solids concentrations has been developed for driling conditions. Acceptable levels of solids concentrations, appropriate for clean-ups can be developed based on hindcasting studies. For Shell Expro, the EzClean program focal point is Jack Emmen, UESC/6. The following graphs, output from EzClean, show the kind of modelling that can be Performed to simulate well clean-up. The example is based on 0.25" cutting size Figure 1 shows the wellbore configuration with the clean-out string Figure 2 shows the cuttings concentration after driling the 6” hole section. Cuttings are collecting in the open hole, inside the 7” liner and above the liner top inside the 9518" casing Figure 8 shows thal cuttings/solids remain above the 4 1° and 7" liner tops after, circulating with mud at 150 gpm. Figure 4 shows that after displacing to seawater and circulating af 150 gpm, solids remain collected in these Sections of the wellbore Figure 5 and 6 zoom in on these sections and show the flow rate that is required to circulate those sections clean, The required flow rate for the section above the T liner top may be achieved using a MFCT. 7Wie arte ° Figure 1 Wellbore configuration for clean-cut after seiting and cementing the 4 74" liner. Kote kA0308 6 nla Pann cenlngg CStcarttar ab nity hoe . 1 000 10.000 g f se Ez, | ee eI aso sess woml itt i} 0 10 20 90 40 50 Annular Cutnge Concentration Figure 2 Predicted annular cuttings concentration after diling the 6” section, eKeleh KA-0008 - 6 hala Cleanup wih mud [ast Parameter Value Ccutings Coneontraion ater ercoaing YSbxom ty “Bi : r serps | wiopenaegt | Fuga | O8m 5900 Densiyoas Se oe ‘YP (ibs/t00R"2) 23 Sele} 7 vow Sper . Flow Rate (gpm) 180 5 movin) 18000 Ccunege cena rine) 3 TLE) — creuatny [ern ds | 0000 28,000. - 0 10 20 30 40 50 ‘Arava Catngs Cencenitaon Figure 3 Annular cuttings concentration after clean-out with mud (circulating at 150 gpm). ‘acy $A-0308 6 noe Clear wh sn = aos cule Chaaneaion ths Sea Sopp inet Prt ° ae open wes pena) 38 wie ee senna 3.00 compen “Bie Hi wessiooks] of oe Geos, ° « Powel gon) 0 3 norte |S | * 45.000 tonty ott OB OSA credetng Cease ane ta) ae 20,000 4 ? | 2500041 | © 10 20 30 40 50 ‘one Cuings Concentration Figure 4 Annular cuttings concentration after clean-out with sea water (circulating at 150 gpm) »Ket 0908 ne Clan wn ae topPost —| Ve eae | sete Lsasune boars) | sco » nate) 2 Bonen aoa) 10 * mee uc NS |Senyar + ont ete : is, i | veyosiooea) Ss Cites} 8 2 l Operon i L tree : anew & cunngs aman gran 28 Smee) | db Soo 150, 200 280 300 Frow Rate. gom Figure 5 Clean-out with sea water, Annular cuttings concentration inside the 7" liner as a function of circulation rate. A flow rate of 250 gpm is required to circulate the liner section clean, Ketch KA0408 6° no Cesn-yp win lw ‘Citinge Concontaton = 7.800" oomety Maasuedbeom © i Teiratoning) S13 | Bite Py —————j bron aeat | 10 Fue ceri NEE Seam nets) Oss Pvc) Of yeweoore} 6 Ccattngs Cons. % % cating densty ones) 2 Eittngs Damiana) 08 ° “00 200 200 400 300 600 700 Flow Rate, gor Figure 6 Clean-out with sea water, Annular cuttings concentration above the top of the 7" liner as a function of circulation rate. A flow rate of 600 gpm is required to circulate this section of the well clean.Hole Cleaning Operations Hole cleaning operations may be required on the final trip out of the hole prior to mud displacement and chemical clean-up in order to remove all drill cutings so far as is possible. The Operations Maps show the combination of pulling speed and flow rate for pumping or backreaming out ofthe wellbore. The following procedures should be utilized if these operations are required. ‘The far right hand side (low flow rates) of the Operations Maps is not a desirable region of the curve to operate. ‘These Operations Maps are for the wellbore configuration and bit that is indicated on the figure. If the open area around the bit is greater (increase in casing ID or decrease in bit diameter), the pulling speed will need to be slower and may not clean the wellbore sufficiently. Since water is assumed for these operations maps, some cuttings/solid avalanching will o¢cur in the 40 - 50 degree section of the wellbore. Extreme care should be exercised in this section of the wellbore. Possibly pump high viscosity pills when entering thi a section and prior to stopping circulation. * Rotate and circulate one Bottoms up to reduce Cuttings concentration in the iow angle section before pumping or backreaming out. + Select the appropriate figure for pumping out or backreaming out. Based on the actual pump flow rate, determine the appropriate aril string pulling speed in the "Preferred Operating Zone’. For example, if the flow rate is 200 GPM the appropriate dril string pulling speed is slower than 31%z minutes / stand if Pumping out and 2 minutes / stand backreaming out. This is the maximum velocity of the pipe while tripping out. This speed may need to be decreased if sticky cuttings are in the cuttings returns. a+ Pump or backream out at a speed determined in the previous step while monitoring stand pipe pressure and the weight indicator. The standpipe pressure is an early indicator of packing off while doing these operations. IF pressure increases or excessive drag are observed stop pulling, run back into the hole for at least one pipe length (30 feet) and reciprocate the pipe several times while pumping and rotating. Circulate (with rotation) at maximum flow rate for at least one bottoms up or until pressure and drag return to normal. + Continue pulling drill string at a speed in the “Preferred Operating Zone” of the operations maps. + Once the bit enters the lower angle (<40 degrees) section of the wellbore, stop Pulling and circulate at the maximum flow rate with drill pipe rotation until cuttings. returns decrease. This may require multiple bottoms-up prior to completing the trip out of the hole. A high viscosity pill could be pumped at this point to assist in iting the cuttings out of the wellbore. + DONOT attempt to pull the BHA out of the hole without sufficient circulation (with pipe rotation) once pumping out or backreaming out operations have been initiated. A high cuttings bed will form immediately above the bit and around the BHA during these operations. Pulling out without reducing the high cuttings bed will result in the formation of a cuttings plug immediately above the bit, causing pack-offs, lost returns, and stuck pipe. + After circulating at a low angle section of the hole to lift the cuttings out of the wellbore, trip back in the hole with the drilstring without pumping or rotating prior to running the completion.ow Rot gom) eae 32 Heucecrsi (ny $388 | | trenspon cutnge Rosary Spee rem) 1380 St Sory 1309 fin. Ct Oa i) 13 Mix Cue Bam (m) 199 Ps 18 Brparatein, ag Bi Boman) x cia” a ee E Fe Dosey (on me neces = x Preferred Operating Zone | P3886 V55 (hao & Ton Second dean 9 rd “orf wit Bit Manatee Se a eo s ‘bo 00 0s 10 15 20 25 30 35 40 45 50 65 60 68 70 78 Puling Saeed (mint stand) 0 fe ‘Max Inclination (deg) 1000 lax Incination era cans lane B Pia Bae fie ee) 4 ec & eer os me Preferred Operating Zone | FasreNselch).. Ten Second Geto 8 ‘erty wth 2 Manutacturer SESRSRSSRERRERERES rll 00 05 10 15 20 25 30 35 40 45 50 55 60 G5 70 75 Puling Spee (rise) Operations Maps 23 20Summary of Hole Cleaning V All the factors discussed in this chapter should be applied for effective hole cleaning, Address potential problem areas on the last trip out ofthe hole by backreaming, with the correct combination of pipe pulling speed and flow rate, to remove cuttings from the wellbore. V. Circulate at maximum allowable rate. V_ Rotate the drillpipe during all circulating to agitate cuttings and prevent settling. ¥ Ensure mud rheology is within programmed specifications (YZ and 10 second gel >= 10). V Allow sufficient circulating time to clean the well - 1.5 to 2.0 times bottoms up, or even more. 4 V_ Ifunsure consult the Open Hole Quality Team or Production Chemistry for advice: (Contact: Jack Emmen, UESC/6 or Niall MacBeath, UESP/14.) V Utilise EzClean software to predict potential hole cleaning problem areas within the wellbore. ¥ Certain sections of well (e.g. liner tops) may require additional measures to remove solids.B Mud Displacement ‘The success of the clean-up hinges on the proper displacement of the POBM. Clean interfaces between the mud, pills and seawater are an indication of the success of the mud displacement. If the POBM becomes ‘strung out' throughout the seawater J brine, then the cleanup will take longer and you are potentially looking at the scenario of having to deal with lots of contaminated seawater / brine on surface. Circulating and Conditioning Mud Prior to mud displacement, circulating and conditioning is essential for two reasons: Residual debris removal When a clean up string, which inclides casing scrapers, is run in the well to perform the mud displacement / cased hole operations, the scrapers will remove debris from the casing wall and this debris will accumulate at the bottom of each casing section. Sufficient circulation is required, with @ fluid that has lifting capacity, to remove this, debris from the well Improved mud displacement The displacement efficiency is improved with a lower mud theology. The mud should be allowed to reach circulating temperature with the finest screens possible on the shale shakers (200 mesh or fner). This will reduce the effective rheology and remove excess solids from the well. Steps should be taken to mobilise the slowly moving or even static gelled mud present in the deviated section of the wellbore. Due to pipe eccentricity, in a deviated wellbore, flow will favour the wide side of the hole _with static Mud remaining on the narrow side. Mobilisation of the static mud on the narrow side can be greatly improved by + Pipe rotation + Pipe reciprocation. + slncreasing flow rates. + Reducing mud gel strengths and yield point PocenisincenenRheology can be reduced by either dilution with base fluid or by chemical treatment with thinners or deflocculants. In all cases caution should be exercised, 50 2s 10 avoid destabilising the fluid and instigating barite sag. Pilot testing of the proposed treatment is recommended. ¥__ Tools such as Dowell's CemCADE can calculate rheological /flow properties. Mud Displacement Pills The following pills are recommended by Production Chemistry, UESP to be pumped to displace the wellbore from POBM to seawater or brine :~ Base Oil | 30 bbl 50-100 bb! | This pill is used to thin the mud and | prevent gelled mud from sticking to the casing wall. Pil should be ested wih | settlement when mixed with any galled | mud sticking to the casing wall. Push Pill | 100 bbl 100-150 bbI | This pill wll act like a displace the whole mud out of the hole, It will help remove solids that have accumulated on the low side of the + The composition of the push pill should be 3 ppb XC polymer + 3 -5% surfactant in seawater. Aim for YP of approx. 50. + The displacement flow rate should be such that the base oil is in turbulent flow (see tables in Section 3.7) and the push pill is in laminar flow. 23+ Controlled and Uncontrolled Displacements A controlled displacement is performed when an inflow testis required after a liner cement job. During displacement a ‘back pressure’ is held, to ensure that the BHP remains the equivalent to that with the weighted mud in the hole. This ‘operation is performed by closing in the BOP annular / rams on the drilipipe ‘and taking retum flow to the choke manifold where ‘back pressure’ is controlled by the choke. After the well has been displaced to seawater the ‘back pressure’ ‘on surface willbe the difference in hydrostatic pressure between the two fluids. This pressure is bied of in stages and the ‘inflow test’ performed to ensure that the wellbore has pressure integrity with seawater in the well. As the BOP's are closed on the drillpipe, there is no rotation of the drillpipe and therefore the drillpipe remains stationary within the wellbore, mainly lying on the low side. ‘An uncontrolled displacement involves conventional circulation, as in drilling operations, with flow up the riser and directly to the shakers and pits. + Effective Laminar Displacement of the Mud by a “Push Pill” The pump rate of the hi-vis pill is such that it provides an effective laminar displacement of the mud. ~The lower limit of the flow rate is to ensure that flow occurs all around the pipe. = The upper limit of low rate to prevent the interface with the preceding fluid from rising faster on the wide side of the annulus. . Both the upper and lower limits are affected by drillpipe stand-off. Within CemCADE a plot of % stand-off vs flow rate (BPM) provides the upper and lower limits and a stability line. The area above the stability line and within the upper and lower limits shows the flow rate required, at a given stand-off, to ensure a laminar flow displacement in the complete annular area. The laminar displacemnt of the “Push Pill is dependent on: + Mud weight + Mud theology + Casing ID + Drillpipe OD Team Maa Diisiocer:& Drillpipe Stand-off (Pipe Eccentricity) Recommendations for cementing liners and casing usually specify more than 80% casing stand-off for effectiveness of the cement job and mud removal. These recommendations are also considered applicable to pre-completion elean-ups. The 4% stand-off is defined by We x 100, a) J 4 Wa Expressed in an alternative way : ‘ s%= EOD Pipe OD) _ 99 (Casing ID - Pipe OD) Without centralisation the stand-off of most sizes of drillpipe, in a deviated hole section, is below 50%. Pipe stand-off has impact on the flow rate required to initiate fluid movement, critical flow rate for turbulence and the upper limit of laminar flow In order to avoid by-passing fluid. The table below illustrates how poor the ‘stand- off is, with only the tool joint acting as a rigid centraliser. In the table, the figures are calculated for a vertical / low angle well where the tool joint is assumed to lie against the casing without any deflection of the pipe between tool joints, Theory Mud diepiocemen 28ia ea err aco eo) 0 (ins) exo) 6-5/8" 262th, $136 | 8.0 | 10-514" ssibk| 9.760 | 44 6-5/8", 25.2 lbh, $135 | 8.0 | 9.5/8", 47 Ibi | 8.681 67 5-1/2", 24.9 bi, S135 7.0 | 10-314", 55 Ibn | 9.760 35 542" 21.91bit, S135 7.0 | Sse 47 ibm | 8.681 a7 5", 19.5 Ibitt, $135 6.312 | 10-34" S5ibiR| 9.760 26 5), 19.5 bo, $138 6312 | ssiea7ib | 6.68 $135 | 5.100 | 9-5/8" 47 Ibi | 8.681 3 "15.5 Ibi, $1355.10 342 7 23ibh 6.184 60 |3-1/2", 13.3 o/R, $135 | 4.812 | 9-5/8" 47 bt | 8.681 3-112", 13.3 1bt, $135 | 4.812 | 720IbR | 6.184 2716", 1041b/, S135) 30 6.184 2-718", 10.4 lof, $195 | 3.0 | 5%, 46 ibin 4276 A graph showing the effects of wellbore deviation is shown in Appendix 2 These plots were generated by adding deflection of the drilpipe tube, using the fixed end supported beam theory. In this theory the drillpipe is assumed to be supported at the tool joints. The deflection, 6, js calculated using the following engineering formule j= Wilt sing 3847 ET In oilfield units this formula becomes =~ “Lt *sin@ ) where W = drilpipe weight (Ibvft) L_ = length between tool joints (ft) @ =hole angle (degrees) Dz = drilpipe OD (ins) D: = drilipipe 1D (ins)The effect of tension, which would reduce the deflection, has been ignored in the calculations as the effects will be small in a deviated well. The calculations provide a worst case scenario. The graph shows that wellbore deviation has the greatest effect on the stand-off figures for the smallest drillpipe, which is expected due to the reduced stifiness The connection dimensions for the 2.’/s" drillpipe were based on the Hydril WT23 connection, which is normally selected for its torque rating. However in a high angle/ horizontal wellbore, the connection provides very litte stand-off. For pipe / casing combinations not covered by the graph in Appendix 2, calculations can be performed using the given formula. In addition an Excel spreadsheet to do this can be found on the Ivory server. Annular Flow Profile ‘An uneven velocity distribution in an annulus, due to eccentric drilipipe, can cause the possible co-existence of different flow regimes. The Reynold’s Number (Re) of a fluid with no yield stress (Newtonian) is dependent on the fluid velocity and annular, gap. Both are larger on the wide side than the narrow, as is the local Reynold’s Number. Therefore the flow regime may vary from laminar to turbulent across the annular section. Examples of Newtonian fluids are water and whisky (no solids present in the fluid). Most drilling fluids fall into the category Non-Newtonian. For non-Newtonian fluids, three flow regimes can co-exist :- + No flow on the narrow side due to the mud's yield stress. + Turbulent flow on the wide side. + Laminar flow in between the above two areas. Increasing Flowrate ———» 93090 [ih Few Laminar Fiow ll Turoulert Fiow 30‘Shear stress experienced by a fluid at the wall of the pipe is a function of the velocity profile and therefore varies across the annular cross section, from a maximum at the widest annular clearance to a minimum at the narrowest. The fluid is stationary if the shear stress at the pipe wallis less than its yield stress. This change in annular velocities, due to pipe eccentricity (stand-off), alters the annular flow profile Depending on the fluid rheology and drillpipe stand-off, the fluid may eventually cease to flow on the narrow side of the annulus. Conseil 75% Consentie 50% Concentric 25% Concentric ocity 20) 18 1 19 1 I b 3 o Pipe Rotation / Reciprocation In a highly deviated well with the drillpipe tying on the low side of the hole, gelled mud can become trapped. The figure adjacent indicates ‘a generic flow velocity profile across an annulus with eccentric drilpipe: Flow favours the high side of the hole and two “stagnant” flow areas exist (at A& B). Peak velocity / Mean vel ¥__ The action of drilipipe rotation disturbs the gelled mud and re-introduces it into the higher flow stream area of the wellbore. V__ Rotation can improve “stand-off when compared to the “stand-off figures for stationary drillpipe by eliminating (or reducing) the deflection between the tool joints. V _ Ifrotation cannot be accommodated, due to torque limitations, centralisation Of the drillpipe should be considered, e.g, by use of stabilisers or centralisers. V__ Dowell's CemCADE can model the effect of stand-off / centralisation 1Critical Flow Rate ‘The Critical Flow Rate is the minimum necessary circulation rate to initiate and maintain the flow of mud in the narrow side of an eccentric annulus. The plots given in Appendix 3 were generated by calculating the displacement efficiency of the mud by itself, using Dowell Schiumberger's CemCADE program. Mud weights from 550 pptf to 950 pptf were considered, to show the effects of mud weight and the corresponding increase in solids and plastic viscosity (PV). The following table shows the parameters used for generating the plots in Appendix 3. Important points = + With decreasing stand-off, the critical flow rates become progressively higher. + When the stand-off figures calculated in Section 3.3 are considered, very high flow rates are required to move the mud in the narrow annulus. If Grillpipe centralisers are not deployed, pipe movernent (reciprocation and rotation) has to be used to improve stand-off and bring the static mud into the flow stream, + Reducing the rheology of the fiuid also reduces the shear stress, and hence the flow rate, necessary to initiate flow.‘The table below summarises the critical flow rates (in bpm) to move the mud in the narrow side of an eccentric annulus for the more common drilpipe / casing combinations without rotation. Mud Weight (ptf) sting sia" | 36 22 20 19 Z 15.5 aiinm | 6 | 65 | 45 | 40 | 35 | 35 27erins’ | <0 | 65 | 60 | 55 | 50 | 45 Turbulent Flow Displacement The flow rate at which @ fluid goes from laminar to turbulent flow is determined by the Reynold's number equation = _ PVAd a where P= density ,V = annular velocity, Ad = diameter, I= viscosity, Res and Ad generally cannot be changed in the well, thus Re = f (Vin) ‘To maintain a high Re number, i.e. turbulent flow, then V should bé large and 7) should be small When oilfield units are applied the equation becomes: 928PVAd 7 where P= fuid density (pp9).V = fluid velocity (R/sec), Ad = casing ID - pipe OD (ins), = fluid viscosity (cp). Res Ithas been experimentally established that at a certain critical value of Re the flow pattern changes from laminar to turbulent. «2100 2100 - 3000 >3000 3Pump rates (in bpm) required for turbulent flow, for various drillpipe / casing configurations and stand-offs, are tabulated below and presented graphically for base oil and seawater respectively in Appendix 4. The importance of ‘stand-off is again highlighted when the figures noted for pipe eccentricity in Section 3.3 are considered. Dowell Schlumberger’s CemCADE was used to calculate these flow rate figures. Clean base oil has a viscosity of 1 cp, however 5 cp is used by Dowell in ComCADE to allow for contamination Dat [658/65 [S12 sae st | & [anna] ore) 270 Pipe | OP oP | oP pe op | op op | oP | P| OF Stanc-|Casing 103M"/ 95 [l0sw Sas OAs] see ese | 7 |r |S at] sue [ssn |ne| sue 7mm ssi |4rbm 7b | ab] zon 1D [8760 | G661 [9760 G68 | 9700 |a.6at | 868 | 6.164 | 6184] 4276 wo| |_| || [Foo | 24 | 23 | 22 | 21 | 22 | 20 | 18 | 14 | 13 | 44 75 41 | 3a [se | se [37 | a4 | 31 | 24] 23 | 18 50 [es [ea [aa [77 [at [7s | 67 | 53 | 50 | 39 45 too | 102/102 | 94 | 99 | 91 | a2 | 65) 61 48 40 436 | 127 | 127 | 18 [123 | 14 [102 | 04 | 76 | 50 2 a [192 | 93 [151 | 8 148 | 131 | wa ey | Ta % B41 | 215 | 26 | 200] M0 | 194 | aa | ter | 128 | Tor 25 | 243 | 194) 180| 140 = | | 362 | 205 | 268 | 209 8 #87 | 4a | 2a | aa] 15 w2 | a7a| as) Me Table 3.7a - Pump rates in BPM for turbulent flow with base oilpnw ese Jes [saz se) os | 5° [a-w2"| a12"| 276° 2-716" | Pie | OP | OP | oP | oP oP | oP | op | oP DP OP Sard lCasralioair osm 0am Saw Toa vam loam TTF off (%)] Size | Sst 47IbIR SSE 47Ibit SSibif | 47ibrft 47tin | 2etbit|2atbyn tee ID [9.760 8681 | 9.760 |8.681 9760/2681 |esat | 6184 | 6.184) 4276] (ins) | Cy m= | [a1 2828 | 2720 | 26 [er [62 | 62 | se | 60 | 56 | 50 | 40 | 37 | 20 [2 |e | 76 | 71 | 74 | 68 | 61 | a8] 45 | 36 [2/95 9s 08 | 02 | 130/24 22) 3] 18 | 109] Wa | ier 12 | 10 | te7 | 145 | 190 | 103] a7 | Te I 182 | 143 | 184) 108 |__[2ra [2a | 20a | 157 327 | 267 | 242 | 129 [450 | 354 | 333 | 260 Table 3.7b - Pump rates in BPM for turbulent flow with seawaterSummary of Mud Displacement Vv The success of the clean-up hinges on the proper displacement of the OBM. V Prior to mud displacement, thorough circulating and conditioning of the mud is essential Mud displacement pits should have the base oil in turbulent flow and the push pill in laminar flow. V The mud displacement process during cased hole clean-ups should utllise, wherever possible, the current best practices adopted during drilling and cementing operations. ¥ The charts and tables included in this chapter can be used to determine the effects of drilpipe stand-off. Calculations for other drilpipe / casing configurations can be performed using CemCADE. V__Diillpipe stand-off eccentricity) has a significant effect on :- = Annular flow profiles ~ depending on the fluid rheology, the fluid may cease to flow on the narrow side of the annulus - Fiow rates to initiate flow on the narrow side of the annulus ~ Critical flow rates for turbulence + Upper limit of flow rates to ensure a stable push pill V__Drillpipe rotation (60 - 1001pm) is essential in deviated wells - ~ To disturb the gelled mud lying on the low side of the hole and introduce it into the higher flow stream area of the wellbore ~ It is an aid to improve the negative effect of drillpipe stand-off V _ Hfrotation cannot be accommodated, due to high torque limitation, centralisation of the drillpipe should be applied by use of centralisers or stabilisers. V High flow rate with drilpipe rotation is essential for efficient mud displacement ~ controlled displacements are non-ideal. 36|4.0} Chemical and Mechanical Clean-up ‘The aim of the chemical / mechanical clean-up is to displace the drilling fluid from the wellbore leaving the casing ‘water wet’, before displacing the well to the completion fluid (inhibited seawater or brine). The detalled process for a cased hole clean-up may vary but generically follows on from driling a reservoir section, running and cementing a finer or casing and cleaning the surface and sub-surface equipment prior to commencing the running of a. completion string (On completion ofthe driling process, and with the liner or casing cemented in piace, the welt is usually left full of oily mud. The mud generally consists of an cily base: fluid, to which water and clay have been added for viscosity. Barite or dolomite is added as a weighting agent. Its suspended in the mud to raise the density, hence imparting a higher hydrostatic pressure. The oil phase contains emulsifiers, which are powerful oil wetting agents. These ensure that all surfaces (tubulars, barite, formation) are oil wet and any water is encapsulated as microscopic droplets. When displacing the well to water, not only does the oily mud require displacing, but also the casing surfaces need to be changed from oil wet to water wet Note: Water alone will, not remove oily mud. The cily mud is removed by pumping solvents, to dissolve any oily residues, and surfactants (surface active agents) to change the casing surface from oil wet to water wet, .6. counteracting the emulsifiers in the oily mud. The chemical pills are pumped ‘at maximum pump rate to generate turbulent flow, with a 10-minute contact time. desired. The wells then displaced to inhibited freshwater, seawater or brine, depending on the completion requirements. 7Description of Fluids 4.4.1 Olly Muds These are invert emulsions, where the continuous phase is oll, to which water or brine is added. Emulsifiers generally have @ polar head, which is soluble in water and a non-polar tal, which is soluble in the oil. The tail exerts the greater influence, so that the molecule is soluble in the oll phase. Due to its nature, the emulsifier moves to the oil / water interface, encapsulating the water as microscopic droplets and stabilising the invert emulsion. The emulsifiers also coat the well surfaces - tubulars and formation, and also any solids incorporated into the mud - weighting agents (barite, dolomite), clays and formation 4.1.2 Solvents Solvents are chemicals which dissolve the oily mud. The simplest solvents are the mud base fluids themselves. These reduce the viscosity of the mud, dispersing fitter cake and settled cuttings or weighting agents (barite, dolomite). Mutual solvents have both polar (water-soluble) and non-polar (oil soluble) parts. Both parts exert similar influence, so they are soluble in both oll and water. They are usually pumped as dilute solutions in water. Dilute solutions of mutual solvent are effective in removing thin layers of oily mud. Unless they are pumped highly Concentrated or neat, they are NOT effective against thick layers / large amounts of olly mud. In these cases base fluid is more effective (and lower in cost.)4.1.3 Surfactants Surfactants are surface-active agents. In the oilfield, surfactants are synonymous with detergents. However. in reality, they inciude emulsifiers as well. For the purpose of this guide, the term ‘surfactants’ is assumed to refer only to detergents. They have Polar heads, which are water-soluble and non-polar tails, which are soluble in the olly layer. Contrary to emulsifiers, the polar head exerts the greatest influence, so the molecule is water-soluble. Surfactants encapsulate cil allowing ito be dispersed into the water and will displace oil from surfaces, rendering the surfaces water wet. Shown below is @ schematic of a surfactant molecule and a representation of surfactant attack on an oil droplet. These pictures are reproduced from the Dawn Chemical company website, Surfactant molecule Hytrophete en —______O) Hyerepie ond p. eee een ee as P v at Ory Sot Beton ata oc Boosttrts be = 5 ee g t rerio of resile Sanaa nd Peconic ene serpaned ed peed 4.1.4 Flocculants Floceulants are chemicals which cause dispersed particles to clump together ie. flocculate. Whilst flocculants may help in removing the final traces of drilling fluid / oily particles, experience has shown that use of flocculants can significantly increase the time taken for a well clean up, with many circulations being required to remove all the solids,4.1.5 Tables of Chemical Products Oily Mud Systems Name Type Carbo SEA Low toxicity Oil Based Mud Versavert Low toxicity Oil Based Mud BaraKleen Low toxicity Oil Based Mud Kleemnul Low toxicity Oil Based Mud Synteq ‘Synthetic Oi Based Mud Versaplus ‘Synthetic Oil Based Mud XP-07 Mud Ecomut ‘Synthetic Oil Based Mud Uti ‘Synthetic Oil Based Mud Supplier Baker Hughes Inteq (BHI) MI Drilling Fluids Baroid BW Mud BHI M-l Drilling Fluids Baroid BW Mud Mul Drilling Fluids / Dowell There are also ester based systems ¢.9. Petrofree, but Shell does not use these. Solvents Name Type Parateg, Isoteq Synthetic Base Fluid Ultidril, Versa plus Synthetic Base Fluid Ecosol Synthetic Base Fluid XP-07 Synthetic Base Fluid EGMBE Mutual Solvent ues Mutual So'vent Musol Mutual Solvent RX-03 Mutual Solvent RX-098D Mutual SolventSurfactant Blend Safe-Solv OF Solvent, Gold Flush tl Solvent Baraklean NS Plus Solvent Enviroclean, Mutual Solvent Wellwash 410 Solvent Supplier BHI M-I Drilling Fluids / Dowell BW Mud Baroid Verious Dowell Halliburton Roemex Roemex MAI Drilling Fluids, Deep South Chemical Baroid BW Mud OscaSurfactants Name Tetraclean 105/106 Goldsurt 11 Barakleen FL Plus Envirowash RX-16/1 Safe-Surf Hymul Milclean Wellwash 510 Flocculants Name Envirofioc Supplier TETRA Technologies Deep South Chemical Baroid BW Mud Roemex MAI Drilling Fluids ‘Schlumberger (Dowell) BHI OSCA Supplier BW Mud B Description of Mechanical Tools Mechanical tool strings comprising generally of a scraper, a brush or a combination ‘of both have been introduced over the years as an aide to the chemicals during the clean-up process, Fig. 1 SPS Scraper | Fig. 2 Baker scraperScrapers Conventional scrapers were developed many years ago to knock off lumps of cement after aborted cement jobs and to repair perforation damage by knocking off casing burrs. These scrapers were never intended to be used to clean casing ID's in preparation for running production and test packers and installing other production completion equipment. Historically these conventional scrapers have been used for clean-up due to their being the only too! available until the appearance of the newer maxi-contact scrapers that have recently become marketed Tests have been performed with some conventional metal bladed sorapers that concluded that they were only effective at scraping 30%-40% of the casing circumference. Because the curvature of the scraping blocks does not match the curvature of the casing ID, it can result in 60-70% of the surface not being touched. Maximum contact tools such as the SPS Razor Back™ have been developed specifically for cleaning casings and liners during well bore clean-up operations. ‘These tools are regarded as being more effective and more robust than conventional casing scrapers. Tests specific for Shell Expro's Shearwater operations using a 9 5/8" SPS Razor Back"™ scraper and a 9 5/8" Brush Type™ supplied by SPS were undertaken during Nov. 1998 at a local test well. The tests concluded that these tools wate effective at cleaning heavy cement sheath and mud film as well as heavy rust / scale bulld- Up whilst remaining robust enough for the most demanding clean-up operations. ‘The SPS Razor Back™ has been designed to make much greater contact with the ID of the casing, up to or in excess of 20% of circumference as compared to 30- 40% by conventional scrapers. The strong, self-centralising, flexible lantern with a scraping profile machined onto its OD flexes with the slightly changing ID and ovality allowed by API in most casing, thus maintaining a high degree of contact at all angles of inctination, A further downside of a conventional scraper is that the blades are spring loaded which will tend to depress the blades on the low side of a highly deviated well and reduce / remove the scraping action on the high side of the wellbore. For this reason 4 soft bladed stabiliser is offen run behind a conventional scraper to centralise the scraper. The SPS Razor Back™ has integral stabilisation ryBrushes Brush tools have also been developed as a mechanical aid for wellbore clean-ups. The current belief both within Shell Expro and other operators is that brushes are rat the complete answer to well bore cleaning, but are tools that can be used in Conjunction with other tools when desirable. Opinion on using a brush in conjunction with a scraper, in the casing or liner sizes in which packers are to be set, is that it is a ‘belt and braces’ approach which can potentially achieve a higher degree of Cleanliness i.e. combining a scraping and scouring action. Fig, 3 Bristle BackT’ SPS Brush Circulating Devices Circulating devices are sometimes included to enhance flow rates and create higher annular velocities. These tools have been developed for wellbore clean- Ups to boost flow rate above a liner or other casing ID restrictions when a ‘smaller diameter drillstring is in the liner and the pump rate is restricted because Of the pressure drop. Fig. 4SPSMFCT Fig. 5 SPS SABSFor Shell Expro operations the main circulating devices currently used are the SPS Multi-Function Circulating Tool (MFCT) as outlined in Fig.4 and the Single Action By-Pass Sub (SABS) shown in Fig 6. 4 types of MFCT are available: - (1) Standard, (2) with Bearing, (3) with Clutch and (4) Locking type. A brief summary of the tool features is given in the table below :- Developed for use in wels where dling fs necessary and high cculaton FCT (standard) |» | tes are requred | + Operated ina similar manner as bumper sub + Fully stroked out while running inthe hole and any erculaion goes | through the ditstring + Whom the required weight i sacked off, the outer sleeve movas down, opening the ports and allowing the fluid by-pass to be activated, | +The toot maybe shear inne in place (20,000 - 69,000 bs shear), | required, prior o frst activation “MECT |= As standard plus (with bearing) + Abearing sub can be run allowing rotation of the whole string after setting down weight to open the circulating ports, ‘ MFCT + Asstandardplus; (orth clutch) + By specifying @ tool with an internal clutch mechanism rotation of the {rilsting above the tool, with the tool in the open position, can be achieved. Whilst protecting the lower string below from potentially damaging tora MFCT | + Developed for use in wells where milling / diling is necessary and (locking type) high circulation rates are required * Tool has an automatic and continuous *J* mechanism that alows the Ports to remain open every second time the tool is landed out then picked up. This allows the tool to be picked up in the by-pass open Postion and reciprocated and rotated until tis landed out and the “Jt Position changed. The tool will subsequently move to the closed Position in the up stroke and circulation goes through the end of the nil sting.Within Shell Expro the clutch and bearing types are the most common types run, depending on whether rotation of the drillpipe below the MFCT will be possible, The MFCT's are available in a range of sizes to suit the different wellbore configurations, a8 outlined in the table below. cca 10%" & 9%" a The SPS Single Action By-Pass Sub (SABS) can be run in a casing clean-up string where it is desirable to boost flow velocity in a casing string above a liner or casing crossover, when another smaller liner exists and an MFCT is already being utlised The tool is run in the closed position and when required a ball is dropped to open up the sub. If required a second ball is dropped to close the sub. Where there are for example 9 6/8", 7" and 5" liner sections in the wellbore, hydraulic calculations will determine if adequate flow rates can be provided in the 7* liner section. If not it may be beneficial to run a SABS. Jetting Tools Jetting tools for cleaning the BOP's and riser have been developed to flush these areas prior to the mud displacement and wellbore clean-up. The aims to dislodge and remove accumulated cuttings and debris with a jetting action and higher annular velocity. Ideally this operation is performed when the mud is cold with a high viscosity to increase carrying capacity,Well Patroller The SPS Well Patroller™ is a further wellbore clean-up tool designed to be run in the clean-up string and completes the clean-up by filtering the remaining debris from the annulus through a wire screen fiter. As the string, complete with the well patroller is run in the well the diverter cup / wiper wipes the ID of the casing. On pulling out of the well, the diverter cup / wiper again wipes the ID of the casing and diverts the annular fluid into the tool. The fluid fiters through the wire screen fiter jacket and any remaining debris is retained. Ifthe assembly is filed with debris an emergency by-pass (rupture disk) can be activated. Fig.6 SPS Well Patroller Gauge Ring The casing in which the production packer is to be set can be drifted, to simulate the stiffness of the packer / packer setting tool. Use of a soft bladed stabiliser or alternatively an SPS Pozi-Drift Sub can be incorporated in the clean-up assembly {0 simulate the packer configuration. This tool should be run above casing scrapers / brushes to ensure the casing has been cleaned prior to drifting with the sub.Areas for Clean-up ‘The following areas of concern have been identified and need to be addressed in an Optimum Well Clean-up Process : 1 2 3 Surface systems: Drill floor, mud pits and circulation system. ‘Subsurface: Riser, BOP's and wellhead. Subsurface: Casing / liner strings - ‘Surface - Areas of Concern = a | = sat | Subsurface - Areas of Concern Riser4.3.1 Surface Systems Industry wide data has shown that a surprising amount of completion NPT has been caused by dirt and debris being pumped back down the well post clean-up. This is obviously highly undesirable. To prevent this requires extra attention from all n phases, particularly before personnel involved in both planning and executi pumping the clean-up sequence of pills and sweeps. The following areas are ‘examples of those needing to be addressed: Drill Floor, Mud Pits and Circulation System. Drill Floor: Debris common in this area can be of two types: - Intentional — Any material that is deliberately introduced in the well as part of the well operations but which need: to be removed prior to insiallation of the completion (e.g. barytes, cement, pipe dope, cementing 198, milling ewarf, etc.) Accidental ~ Any material unintentionally introduced in the wel (.g, croppad objects, parts lost or broken off from driling tools, chunks of BOP rubbers or equipment sealing elements, etc.) Mud Pits and Circulation System: |! is essential to ensure the cleanliness of all the pits and lines and remove as efficiently as possible mud residues, pipe dope, etc, The ideal solution is to erat cate all such contaminants from all metal surfaces, Which are likely to interface with the fluid being pumped downhole. 484.3.2 Subsurface Systems Focus should not only be on removing cuttings and debris from the casing strings but also the additional subsurface connecting conduits such as riser, wellhead and BOP's, For the latter items a full bore jetting sub is the best clean-up tool to use. Performance Measurement ‘Almost without exception the success of the well clean-up operation is assessed by ‘measuring the percent solids content of fluids returning from the well. Occasionally the NTU count is measured with a turbidity meter as secondary confirmation of having achieved a clean well. Unfortunately, neither of these measurements gives an accurate measure of how ciean the well is down hole — they merely measure the cleanliness of the water returning at surface (Appendix § offers more detailed explanations of turbidity and solids content measurement for the non-chemists). Current definitive performance measurements onsite are NPT and “Train Wrecks” in the weil completion phase. There are 2 aspects of note; one is measuring success in retrospect, the other is measuring success in real time downhole. The latter is the challenge and has proved to be the current weakness in the available tool armoury, 49What are the best indicators to assess well cleanliness ? + Quick and easy to use. Measures ONLY the cleanliness of the returning fluid (which might be flowing past debris let downhole) + Use of SPS Well Patroller ? + pulled clean, then good indication + Use of turbidity and % solids measurement ? area sampled above tool is clean, + Ifpulled full, itis an indication that a further clean-up is required. + Torque increase? + Indicates the removal of lubricant ie. POBM. + Evidence of rust ? /— [+ Ingication that casing steel is water wet = Clean-up assembly pulled clean? | indicator that all appears OK. tdWhat other tools give indications of well cleanliness ? Use of Schlumberger USIT? |= Primarily run to identify casing wear but proved (In Shearwater project) to be useful in confirming if the wellbore is free of any mudcake or cement. (Further details given in Appendix 6.) + Use af caliper ? | For quantitative comparison pipe | would need to have been callipered |___ prior to introduction of driling fluid, + Has proved to be useful for removing small shavings of metallic debris Use of magnet ? Agreement has been reached within the industry that currently there is NO 100% definitive tool available. Further liaison between the Clean-up Focal Point, service contractors and equipment suppliers to develop tools that, by ‘appliance of science’, will enable us to see the debris downhole is regarded as being essential (i.e. Particularly before inteligent well systems become the preferred option for completions).& Recommended Cased Hole Clean-up Procedures The following three chapters describes some engineering aspects that should be employed during the clean-up process and recommends “best practioes” as determined by the Shell Expro Clean-up Task Force for equipment selection, chemical agents and operational procedures that should be applied for each activity in a cased hole Clean-up. As to an industry "best practice’, the Task Force found this does not Currently exist, Several operators have recognised the problem but none has so far developed ideal solutions. There is also a lack of an integrated solution provider ite, one offering chemicals, mechanical tools and clean-up programme design engineering services. There is no one generic clean-up package to fit every well scenario. However to obtain the optimum clean-up, factors need to be considered as early as the well Planning stage. If the well design cannot accommodate the requirements for an Ccptimurn wellbore profile [rom a cleaning point of view) then atleast the consequences fo the cased hole clean-up needs to be recognised and addressed. ‘The key factors thatthe designated person developing the well clean-up programme hhas knowledge of the pertinent factors that are important to allow them to apply an engineered approach, Well Planning As with all Well Engineering processes the key to attaining a successful operation 's by applying the SPs ie. Proper Planning Prevents Poor Performance 5.1.1 Gathering Data ‘The clean-up process should commence with the Well Engineer gathering and documenting all pertinent well information. A format for this data collation is given as Form A in Appendix 7Examples of the salient data are listed below = General Data + Well name, well ype ie. Platform / Subsea, + Oilproducer / gas producer / water injector / gas injector. It may be that injectors or producers perforated underbalanced are less tolerant of gunk, particularly in the liner. + Well geometry: Are the planned well angles going to make certain areas of the well more dificult to clean ? + Casing sizes, weights, grades and setting depths. + Deviation plan / well path / deviation survey file. + Sidetracks or mult-lateral branches Fluids + Mud type and properties (mud in hole prior to clean-up), + Displacement fuid to be used and properties. + Packer fiuid to be used and properties. + Compatibility of diferent fuids. Reservoir + Hole conditions / bottom hole temperature and depth / bottom hole pressure. + Reservoir permeability / susceptibility to impairment / intended method of perforation. ‘Completion design + Cemented liner / slotted liner / wire wrapped screen / pre-packed screen. + Conventional / inner string liner cementation. + Completion material - carbon steel, chrome, plastic lined. + Tubing size, weight. grade. + Tubing completion accessories and their dimensions. + Single / dual tubing + Astificial lit - gas lit, ESP, hydraulic pump. + Tolerance criteria of tubing hanger. Rig equipment specifications + Number, size and pressure rating of mud and cement pumps. + Number and size of mud tanks. + Torque capability of rotary / top drive. + Drill pipe sizes available, + Deck storage area,5.1.2 Use of Shell Expro Well Engineering Software. ‘A most important aspect of an engineering approach to cased hole clean-ups is performing engineering calculations to determine the optimum equipment selection / configuration and the clean-up operational parameters that can be achieved for the most effective execution of the job. These calculations require application of computer programs. From a review of the current well engineering software it was noted that there is no single software program available within Shell Expro that focuses specifically on wellbore clean-ups. No one program addresses all issues like the ability to rotate the drillpipe, or whether the cuttings are successfully transported from the well, or ‘that will suggest the optimum volumes and concentrations of clean-up chemical pills and their required contact times. However, for the well engineer who wants to design the optimum well clean-up, there are two excellent Shell developed computer programs available that can greatly assist with the engineering of a successful clean-up. These two programs are Wellpian for Windows and EzClean. Wellplan has several modules but the ones helpful with clean-up calculations are Torque & Drag and Hydraulics. A valuable recent addition to Wellplan for Windows is MoDrill which is Shell proprietary software that integrates Torque & Drag and Hydraulics because both operations influence each other. The cementing module can be used for multiple fluids (densities and rheologies) and will provide surface pressures and ECD's when circulating these fluids. This module also contains an animation feature. EzCiean looks at hole cleaning ie. the transport of solids (cuttings, scale, cement, tc) from the wellbore, and will give annular pressures and ECD's. With the output of this program one can predict whereabouts in the well solids removal will be most dificult. With this knowledge one can evaluate the most effective methods to remove solids from these sections of the wellbore.A third program, which can be of benefit, is Dowell's CemCADE. This software is, mostly known for its use for cementing operations. However, CemCADE also has a "Flow Calculator” which will predict flow regimes in annull. CemCADE has @ feature that allows the stand-off ofthe drilstring from the borehole wall io be calculated (wich none of the above programs can). However, the proprietary issues attached Program means currently only Production Chemistry, UESP, personnel are permitted to use the program. 5.1.3 Use of Shell Expro Databases on IVORY Server & Wells Global Network With the establishment of the Clean-up Focal point, technical data in relation to clean-up tools and chemicals, optimum clean-up BHA’s for different well designs, best practice procedures, including this ABC of well clean-up, lateral learning material, Performance statistics, etc. has been placed in the shared data area of the IVORY server. The IVORY server is accessible by third parties outside of Shell Expro's Tullos office and hence the information can also be reviewed by Shell's contractors and suppliers. The responsibility to maintain and update this data will be with the Clean-up Focal point . NOTE: For Shell personnel refer to your IT focal point / REQSERVICE, and ask for access to: "ABESTPIVORY\datalShell Completions”. For those entering the system from outside Shel, your contract sponsor will arrange for access to be provided by the Shell IT department. The IVORY server data should be viewed as an essential tool at the planning phase to ensure any lessons learned from previous operations are obtained. Additional Sources such as End of Well Reports (EOWR), service contractor job reports (i.e Roemex, Tetra, SPS, BHI, etc.) and the Wells Global Network (WGN) Alta Vista Forum should also be referenced.NOTE: The WGN is @ mult-disciplinary network focused around wel issues. The AltaVista Forum Is the principal collaboration tool and data repository for the community. It sits on the EP Global ssrver, the only collaboration site thatthe whole Shell EP community (including Shell Oil Company) can routinely access. Further detals and assistance can be obtained from Simon Seward, ESM. 5.1.4 Use of Clean-Up Focal Point The well engineer should consult with the Clean-up Focal Point who will provide expert advice and work with the WDT's and service contractors to stimulate greater attention to well clean-ups and help optimise clean-up programmes. By maintaining the Well Clean-up Programme Designs Database, information of previous well lean- ups can be requested and referenced. Provision of performance statistics of mechanical tools and chemicals can also be obtained. 5.1.5 Summarising V__ The Well Engineer should complete Form A, as shown in Appendix 7 ¥ Perform Torque and Drag calculations (Wellplan for Windows). Determine torques for desired RPM's with assumed friction factors. Check safaty factors on strength and make-up torque of string components. Note : Completion fluids will generally give higher fiction factors than mud with higher resultant torques after displacement V Perform Hydraulics calculations (Weliplan for Windows). Determine pumping pressures for desired flow rates. Determine fluid velocities, flow regimes (laminar / turbulent) VY Perform Hole cleaning calculations (EzClean / CemCADE). Determine solids lifting capability of selected fluids along all sections of the borehole. To.use the available sofware packages profciently requires a degree of familiarity For this reason itis recommended to make use of the experience that is available from UESC/8 and Production Chemistry, UESP, to run the software (contact: Jack Emmen, UESC/8 or Niall MacBeath, UESP/14). V__ Review clean-up data on IVORY server, EOWR's, Wells Global Network. V__ Discuss planned operation with Clean-up Focal Point . 585.1.6 Design of Chemical Clean-up Process In order to attain an optimum chemical clean-up design process an effective communication chain between customer and supplier needs to be established. Section 5.1.1 outlines a recommencied form to be used by the well engineer to collate needed data to start this process (given as Form A, Appendix 7). Currently 85 % of Shell Expro WDT's use Roemex chemicals and procedures. Roemex chemicals were selected after a technical assessment of proposed clean- up programmes and chemicals, taking account of OCNS group approval by Production Chemistry, UESP. The chemicals, solvent and surfactants have been outlined in Section 4.1.5. Included in Appendix 8 are the Roemex and Tetra technical data sheets for the clean-up chemicals. The basis of a Roemex job design is = 1, Pump base oil prior fo chemicals. 2. Pump 2 high viscosity pill containing solvent / surfactant product 3. Include a water wetting detergent. . 4, Use a collector pil 5. Displace to seawater. 1. Base Oil The best clean-up fluid to start off with is the base fluid - water for water based mud or base oil for oil based mud. The base fluid is the best solvent for that mud. When choosing the volume of base oil, be aware of the logistics of handling large volumes of base oil returns and the effect on the mud system, if incorporated 2. High Viscosity pill with solvent product (3 ppb XC polymer +3 - 5% RX-03) None of the chemicals available on the market will remove drilled solids from the well, What they will do is dissolve oil. To remove any remaining solids a viscous pill combined with high flow rate and rotation is required sr3. Water wetting detergent (5 - 7% RX-16/1) Surfactants are similar to the emulsifiers used in oily muds. Surfactants are surface active agents. in the oilfield, surfactants are synonymous with detergents, however, in realty, they include emulsifiers as well. Surfactants encapsulate cil allowing it to be dispersed into the water, rendering the surfaces water wet. 4, Collector pill (3 ppb XC polymer + 3 - 5% RX-03) The previous pill will dissolve residue but has no carrying capacity and as such should always be followed by a hi-vis collector pill. 5.1.7 Guidelines for Chemical Operations Production Chemistry, UESP, currently advise not to reverse circulate clean-up chemicals since the pills will tend to become saturated by the time they reach the ‘more critical areas at the bottom of the well and hence be less effective at removing the residual oil flm. In addition rotation and reciprocation are not recommended while reversing which is a distinct disadvantage in highly deviated wells. A.10 to 20 minute contact time of a solvent-based wash system in the widest annulus. is necessary to break up residual oil and synthetic based emulsions. Coricentrations of solvents used range from 3 - 5% by volume, and occasionally as much as 10%. The chemical pills are displaced with seawater and once they are circulated out at surface, circulation with seawater continues, at the maximum rate, until the well is deemed to be clean, Pipe Rotation Values between 30 - 90 rpm are quoted amongst the various mud and clean-up vendors, Tetra quote "experience indicates that no additional beneficial effect is forthcoming with rotation in excess of 60 rpm whilst displacing clean-up chemicals”, Suldasnas‘The bottom line is recognition of rotation as an important means of initiating and sustaining fluid movement on the narrow side of an annulus in a deviated well Centralisation is critical to removing mud from the casing Hf rotation is not possible, consider running centralisers or drillpipe protectors in order to hold the pipe away from the casing. Reciprocation Because some of the solids settle to the lower side of the wellbore they are not carried out of the well as quickly as they would be if they stayed suspended in the fluid. When the solids lie on the low side of the well they become crushed by the rotating string. This causes the solids to be ground up and form fines. In an attempt to remove these fines, most mud and chemical clean-up vendors recammend reciprocating a stand during pumping chemicals, Again, taking all into consideration, i.e. if a circulating device (activated by set down weight) is incorporated into the well ‘clean-up BHA, reciprocation of the string may not be practical. The important point is taking all potential aids into account at the planning stage i.e. if no (weight activated) Circulating device is included then recommend pipe reciprocation. 5.1.8 Design of Mechanical Clean-up String Recommendations arising from interviews with the WDT's, discussions with the suppliers of mechanical clean-up tools and other operators are outlined below : - “A clean-up BHA that scours, wipes and has junk catching means is best", Scrapers + The SPS Razor Back™ is currently the recommended casing soraper. Why 2 1. The Razor Back™ has been developed specifically for cleaning casings and liners during well bore clean up operations. These tools are more effective and more robust than conventional casing scrapers.2. The Razor Back™ has been designed to make much greater contact with the ID of the casing, up to or in excess of 90% of circumference, as compared to 30 - 40% by conventional scrapers. The strong, setf-centralising, flaxible lantern with a scraping profile machined onto its OD, flexes with the slightly changing 'D and ovality allowed by API in most casing, thus maintaining a high degree of contact at all angles of inclination. 3. There are no bolts, clamps or threaded-on rings that can loosen, nor are there weak springs that can become damaged and fall off down hole. The too! has No rotating components touching the casing that could damage the casing or the tool. This is particularly advantageous if the string has been set down to open an MFCT and subsequently rotated with the scraper at one position in the Casing. The tool is constructed from a one-piece mandrel with two stabiliser Sleeves trapping the lantern in place by way of a ball bearing race. All the outer components are machined from tubes and mounted on the mandrel - they cannot fall oft 4. Itis extremely robust and can be used when drilling up cement and cement plugs inside the casings without fear of damaging the casing or of fosing parts from the tool, The tool has been rotated during a number of Shell Expro clean- 4p operations and used to drill up during the same trip to avoid extra trips in the hole. 5. The too} hes been designed not to hang up whilst passing through ID changes or through BOP’s, liner top, etc. It has generous tapers at both ends from the Connection OD to the OD on the stabiliser sleeves to allow easy entry into the ‘casing that is to be cleaned, + All'casing ID's should be scraped. * Ensure that the scraper is run below the planned production packer depth and thal ihe area where the packer is to be set is scraped thoroughly.Brushes + Brushes are better able to cope with pipe ovality but certain types available on the market can suffer excessive bristle wear and / or loss — something most definitely to be avoided. + Where a "belt and braces” approach is felt necessary e.g. the requirement to set an HP/HT production packer. The casing that the packer is to be set in should be soraped and brushed using the Razor Back™ scraper and Bristle Back™ brush tool +The SPS Bristle BackT™ is currently the recommended casing brush. Why 7 1. The Bristle Back has a strong, self-centralising, flexible, bristle-impregnated lantern that brushes the casing. The bristles and lantern easily accommodate the slight variations in ID and ovality allowed by API, maintaining a high degree of contact at all angles of inclination. The tool also has built-in stabiliser sleeves and these, and the lantern, are free to rotate. Because the bristle lantern doos not rotate with the mandrel during pipe rotation bristle longevity in increased, and therefore rotation does not cause the bristles to wear dut prematurely. 2, There are no bolts, clamps or threaded-on rings that can loosen, nor are there ‘multiple brush blocks or weak springs that can become damaged and fall-off down hole, The too! has no rotating components touching the casing that could damage the casing or the tool. The tool is constructed from a one-piece mandrel with two stabiliser sleeves trapping the lantern in place by way of a ball bearing race. All the outer components are machined from tubes and mounted on the ‘mandrel - they cannot fall of. aCirculating subs + The SPS MFCT (with clutch) is currently the recommended circulating device. This circulating tool should be run above small bore liners of any length and above long large bore liners to boost annular velocity in the casing above the liner (usually the 9 fs" casing), Why? 1, The MFCT is designed to open and close as many times as required. This is done by simply pulling the drilstring into tension to close and setting down into compression to open, with the only stipulation being that the pumps are shut down momentarily whilst the tool position is moved 2, The tool can be rotated and reciprocated in the closed position whilst circulating ‘out of the end of the string, and rotated while the tool is open whilst circulating out of the ports on the tool. It is important to note that the clutch type MECT allows the whole string to be rotated when in the closed position but only the drilstring above the tool when the tool is in the open position and the olutch is disengaged. The clutch mechanism prevents the skinny string (2 7h or smaller) from being rotated whilst there is no circulation through and around it. This avoids the possibilty of damaging the often weak connections on the skinny string with excessive down-hole torque during the clean-up, whilst stil being able to maintain rotation of the upper string to enhance the cleaning action. 3, The tool is equipped with an intemal shear-ting for the first activation that must be sheared by setting down weight. The shear force can be varied from 7,000 lbs to 20, 40 or even 60,000 Ibs on some occasions, such as the ERD wells for BP at Wytch Farm. However, the common shear rating is 20k. After the too! has been opened for the first time only pipe movement at the tool is required to change the position. SuicetnesOnly rotate pipe when there is circulation around the outside and do not rotate skinny strings below open circulating tools when the flow is above the skinny string rather than through and around it. The MFCT with clutch is recommended, The torque not required to rotate the skinny string can be used to rotate the upper string faster / longer and improve the clean-up. If 10 2" is run above the 9 */s" and 5° DP is used then @ separate SABS circulating sub (ball activated) can be used to boost flow at this area if required SPS Well Patroller ‘The SPS Well Patroller should be run := In the area where the production casing packer (9 5/6") is going to be set. In the area where a liner top completion seal assembly is going to be run through. In all the casing sections where the size is available, in a water injection well. This is to remove the residual material that cannot be removed by chemicals, ‘scrapers and high circulating rates. The Well Patroller tool will then also validate the effectiveness of the clean-up ie. == 4 + A full tool indicates poor clean-up achieved and more effort is required. + Anearly empty tool indicates a good clean-up. The tool is an effective clean-up tool with a wiping action and acts as a validation after the job. Downhole filtering rather than surface filtering may prove to be very effective, The returning fiuid is then a better indication of the wellbore fluid at depth. The riser, BOP's, wellhead and tubing hanger areas should be jetted with a Well Patroller beneath the jetting sub to prevent debris falling down the well. This should be done before RIH on semi-submersible rigs using the Cameron oF Vetco full bore jetting tool and on fixed installations by making short trip with a jetting sub. Jetting should be repeated again once the well fuid returns indicate the well is clean, after POOH and jetting using the clean fluid. The well Patroller should remain below the clean-up BHA during these operations. 6Q. Does running the Well Patroller guarantee that there will be no problems with the completion? A. No. There are a number of elements involved in a wellbore clean-up. The geometry of the well and the sophistication of the completion are primary factors in deciding which methods are employed. What is now probably clear is that use of the Well Patroller in a properly designed clean-up process reduces the statistical likelinood of non-productive time (NPT) due to wellbore debris issues. Casing Drift + The casing that the packer is to be set in could be drifted using an SPS Pozi- Drift Sub whilst RIH for clean-up rather than afterwards with wire-line tool. Junk subs + Where a SPS Well Patroller isnot included in the clean-up string, a junk sub can be included if solid junk is suspected. 5.1.8 Generic Clean-up BHA’s for Subsea and Platform Scenarios During a technical workshop several of the “train wreck" wells were revisited and the BHA's and procedures used challenged by a number of well engineers and service contractors. As @ deliverable an optimised BHA with procedures for each scenario resulted. Two wells, one covering a subsea operation, Well ‘A’, and the other, Well 'B', from a platform environment, are given as a reference in Appendix 8. + Well’A’ Subsea HP/HT horizontal water injector. + Well'B' Platform non-HP/HT horizontal cil producer.Prepare Draft Programme ‘After completing Form A of Appendix 7, receipt of the proposed Roemex / Tetra chemical train, optimised mechanical tool string (SPS / Baker) and feedback from the Clean-up Focal Point, the well engineer will hen be able to prapare a draft cloan- Up programme. This should then be distributed for review and feedback. Distribution list should include Production Chemistry, UESP, Well Clean-up Focal Point, Mud Contractor (BHI), Chemical sub contractor (Roemex / Tetra), mechanical sub contractor (SPS), ‘Shell senior well engineer, and lead contractor for well completion (Halliburton, Ecis). As an aid to writing the clean-up programme a checklist has been prepared for the well engineer to complete prior to issuing a draft programme for comment. This is included as Form B in Appendix 7.& Execution of Cased Hole Clean-up ‘The LOC Well Engineer will write and issue the final clean-up programme following incorporation of feedback on the draft version from those on the distribution list. This should be done within a timeframe that allows for review and discussion of implementation by the offshore WDT. As to the logistics of materials and services this will be co-ordinated by the Well Engineer and associated logistics section. ‘Appropriate timing to allow necessary QA/QC checks of equipment and chemicals should be considered at an early stage. ‘On calling-off chemicals and clean-up tools the offshore WDT's need to ensure all equipment and chemicals are as specified and fit for use before the clean-up operation ‘commences. Surface and subsurface equipment should be "job" prepared. Before carrying out the programme, a meeting should be held with the following offshore personnel :- - LDC Toolpusher = LDC Offshore Driling Engineer ~ Shell Offshore Well Engineer = Well Services Supervisor + Other relevant specialists ‘The objective of this meeting is to :- Discuss the programme = Discuss the special circumstances, welll conditions, equipment, platform / rig constraints, hot work permit requirements, ete. - Ensure all personnel are aware of their specific duties and responsibilities ~ Discuss well safety and actions to be taken in the event of difficulties during the operation. = Confirm rigsite preparation of surface facilities. = Confirm rigsite preparation and checks of sub-surface equipment and chemical pills. nutes of the pre-job meeting shall be taken by the LDC Offshore Driling Engineer, and sent to LDC onshore Well Engineer for reference in post job discussions. Execution of Cean-usEl surface Systems As identified earlier in Section 4.3 both surface and subsurface areas need to be addressed in both the planning and execution phases. Several examples are given below == Drill Floor + Some of the accidental debris can be prevented with improved housekeeping ‘on surface and drill crew awareness raised during toolbox talks, + Ensure verification of all tubing / BHA tallies. An example exists within Shell Expro where a tally error was identified after a clean-up operation. Due to the ‘omission of 2 stands of crillpipe the end result was 180 ft of sump filed with mud / debris and several days of NPT was incurred in removing this debris to continue with completion operations. + Verify ID's / OD's of all clean-up equipment. Further examples where ball activated subs could notbe activated because of drift restrictions have occurred. ‘Once again a less effective clean-up operation resulted as the necessary increase in annular flowrates to remove the debris could not be achieved. + Ensure non-essential equipment is stored away before commencing the clean- up operation, . Mud Pits and Circulation System A cased hole clean-up programme generally is regarded as a straight forward Procedure where results are clearty influenced and improved by having good planning, clean storage tanks and clean surface lines. The cleanliness of the completion fluid being pumped into the well after the clean- Lup operation can be markedly affected by the cleanliness of the surface equipment. A pre-wellbore clean up checklist of the surface equipment should be consulted and completed. A recommended format for this is given as Form C in Appendix 7. Particular attention should be paid to ensure the well and the circulating system are Not re-contaminated after the clean-up. It is very important that all areas coming into contact with the well are cleaned prior to commencing operations and remain 0 during and after pumping operations.EE) Subsurface Systems Section 4.3.2 highlighted the importance in cleaning the subsurface conduits as well as the surface facilities. The following recommendations have been created due to historical problems identified within these areas - + Prior to POOH on last operation prior to commencing clean-up programme, Circulate and condition the mud thoroughly to clear drill cuttings and other debris from the well so far as possible. + The first BHA (# 1) should be prepared to address the riser, BOP's and wellhead areas. This should include an SPS Well Patroller, full bore jetting tool and 2 sizing pig for the annular BOP's i.e. :- SPS Wall Patroller Full bore jetting tool Sizing pig ‘The Well Patroller should be incorporated lowest in the BHA during the jetting operations, to prevent debris falling down the well. The Well Patroller tool will also validate the effectiveness of the clean-up ie. a full tol indicates poor Clean-up has been achieved and further runs may be require. Anearly empty tool indicates 2 good clean-up. « Use this tool as supplied by Cameron or Veteo to jet clean the marine riser, BOP's and wellhead. However, when jetting the BOP’s DO NOT pump at high pressure with the jets directly adjacent to the BOP's as the jet velocity may cut the rubber elements, To ensure full bore through elements of annular BOP's so ‘that chunks of rubber are not subsequently cut off by scrapers, packers and other full bore items. + The BOP's and riser should be jetted prior to the mud displacement. Perform this operation when the mud is cold and has a higher viscosity to increase carrying capacity. + The clean-up programme should clearly indicate the aroas being cleaned e.o.Marine Riser, Fiex joint & BOP Clean-up BHA (#1) Running Procedite& Guidlines BOP Mike up BHA #1 win Carron joing tol SPS Well Siig Pig Petoler ad snr 80° a Filet pari to og crt al ewes Rearainepimpratewhn ita afeerto BoP names | Ful BE te avoid jeting acon cvting the rubber leon Function arian be ra 9 Sg any ei Cheat aight an choke esa eh boot Lower string so that sizing pig pushes ennular rubber back so ' tomscrum towstoee Wel Paver Pump out of hole ting risor with mud at maximum allowable rate, Lay down and empty SPS Well Patroller. Function blindisheat tams to dislodge any debris. The second BHA (#2) should address the cleaning of the casing and liner strings, Peeteenl eee ui 6There is no one generic clean-up BHA to fit every well scenario, However the recommendations for @ scraper, circulating tool with incorporation of the SPS Well Patroller (acting as an effective clean-up tool and for validation after the job) as outlined earlier in Section 5.1.8 should be incorporated into the final design. This optimisation should be performed between the Well Engineer, Clean-up Focal Point ‘and mechanical tool supplier. Once the casing and liner strings have been scraped, chemical trains pumped and displaced with seawater, the next operation should be the recovery of the weerbushing ‘AS part of this procedure, use BHA (# 3) to ensure the riser, BOP’s and wellhead, areas are again jetted using seawater and Roemex/ Tetra viscous pills. This ensures removal of fine debris that may interfere with the tubing hanger seating / sealing surfaces during the completion phase. BHA #3 should comprise of an SPS Well Patroller, full bore jetting tool and wearbushing recovery tool. An example of the procedure and guidelines are outlined below :- Marine Riser, Flex joint & BOP Clean-up Running Procedure & Guidelines 1. Make up BHA #3 with Cameron jetting tool, SPS Well Patroller and wearbushing running tool 2. RIH whilst pumping seawaier at high rate through the jeting tool unt ting tool is below welthead. 3. Reduce the pump rate when jeting adjacent to BOP rubbers to avoid jetting action cuting the rubber eloments 4. Activate pipe rams and annular(s) to dislodge debris. 5. Circulate through kill and choke lines and through booster lines to clear debris, 6 Lower sting o engage wearbushing then pl back il joting tool can jet tubing hanger lancing area clean, 7. Pump train of riser clean-up chemicals and then pump seawater at maximum rate possible 8. _Displace welhnead and riser to clean inhibited seawater, +f. Poon. 10._ Lay down and ematy SPS Well Patrollor 7Reporting and Job Analysis In order to implement continuous improvement the reporting of pre-completion well clean-ups needs to be made more consistent. The recording and dissemination of lateral learning is essential to eliminate mistakes from “cutting and pasting’ of clean- up programs from well to well. Report all data on Form C, included in Appendix 7. This should be completed and forwarded to the LDC onshore Well Engineer and copied to the Clean-up Focal Point. Hold an offshore rig team post-job debrief. Any equipment failures, problematic chemical operations should be detailed in Form C. Ensure proper recording of data in corporate system i.e. WIS. Ensure any samples of sludge / gunk are forwarded to production Chemistry, UESP, for analysis. Roemex / Tetra report (standard contents and format to be agreed) to be presented to LDC Well Engineer and Clean-up Focal Point. EOWR to include clean-up report salient details obtained from service providers. Mechanical tool company job report details to be completed and forwarded to LDC Well Engineer and copied to Clean-up Focal Point for entry to clean-up databases Use Wells Global Network to share lessons leamed.EB] Appendices ‘Appendix 1 Appendix 2 Appendix 3 Appendix 4 ‘Appendix 5 Appendix 6 ‘Appendix 7 Appendix 8 Appendix 9 Shell / LDC Well Engineering well clean-up process flowchart. ‘Agraph showing effect of wellbore deviation vs drilpipe stand-off. Plats of critical flow rate for various mud weights. Plots of minimum flow rates for turbulent flow for base cil and seawater. Helpful Hints to Understanding (1) Turbidity and (2) Solids Measurement and (3) Filtration. Example of Schlumberger USIT tool use in wellbore clean-up. Proposed forms for planning, executing and reporting of clean-up operations. Technical data sheets for Roemex and Tetra clean-up chemicals. Examples of optimised ciean-ups for two generic well typesSHELL/LDC WELL ENGINEERING WELL CLEAN-UP PROCESS - CURRENTLY Planing Reporrg geste * sere ELLASC WEL ENONEERN WEL CAO FROEEEE_ CMY ea SuSEgeeeeee sees sas ES Se se * Sem, ) eee © SOR TEE ee ernest on apenas 9 speeeanere er neentrn cy a a * BLS bxipuaddyAppendix 1 ‘SHELULDC WELL ENGINEERING WELL CLEAN-UP PROCESSe ® @ PH7Ky(Wd) aive Mo1d oSh 00h ose oo€ ost 902 ost oF os o0 oF oz oc or os neon gig) et cea tm ee 09 (%) 4d O-ONVLS OL og sara wratss rea 06 2/4 $5 antes atm aa 65-9 oor (pnwadd oss) LHOIGM GNWYOs ALVA MO14 TVOILIND € xIpueddyosr (Wd) alvy MOTs oor OSE OVE OS OZ Ost OL os i) (%) d40-ONWLS (pnw dd og9) LHOIAM GNW Y¥O4 F1Ve MOT IVOILIND @ @ > xiovadaw(Wada) alive Mond oor ose oe ose 00% ogt ool os 00 oF oz oe Or os og (%) 44O-ONWLS- OZ 08 08 oor (pnwaidd o¢Z) LHOIAM GNW YO4 FLV MOT4 TOLD exipuaddy(Waa) 3iva Mord ose oe o-sz oz ose oor os 00 OL oz oe or EOS 09 (%) sd0-CNWLS OL og 06 ob (pnwadd ogg) LHOIaM GNW YOd 3LVe MO14 TVOILINO @ £ Mpuaddy(waa) 3ivd MOT lose oor ose aoe oct oo os 00 ot oz of or os og (%) ddO-ONVLS OL og 06 ooL (pnwadd og6) LHOIAM GNW YOs ALVA MOT4 TWOILIND € xipuaddy(Wade) iva MOT4 OU WA BL S40 L-t 007] We LH gO 8-2 ~ fas wa 6440 20-2 — ft 8 (@ ad0-ONVLS Surse0 war 2788-8 4K «Zit ——| Byseo wal Ly 86-6 4d..s Bus80 weiss Suse Wal? 86-6 440.089 {Suse0 Wass P60} 40 25-9 + | UALVMVAS - LNSIWS OW 1dSI MOT LNA TINEUNL e @ * Mpuaddy(Wea) ava MOT sz oz sh on J9un Wa 81.6 Wad 817 > s9un Wa 62 dO 8H = Surg Wa 62 2 Had ZI ——| Suse Wal 2¥ 0156 HAO ZI Surg Wa LP 8168 dd S| Buse Wel 95 -K-Ob Wd .S (%) 430-0NWLS fuse9 Wal Ly .215'8 HAO .ZI-S use Wa $5 27-01 Had ZS Buseo wel 2725 6 MAO ISO = Buse> WA $5 ./t-01 dO 2159 —+— Wo ASV - LNAWAOVIdsIG MOTd LNSTNGYNL 06 oot y MpuaddyRopendix fo] Helpful Hints to Understanding (1) Turbidity and (2) Solids Measurement and (3) Filtration Introduction The objectives of the following "Helpful Hints" are: - + To provide an overview of most common methods used to monitor the cleanliness Of the fluids in a well + To provide an overview of the technique used for Fluids Filtration.Appendix 5 Section 1 Turbidity + Ifawellis not cleaned-up successiuly, the remaining debris can lead to significant problems and associated cosis. These problems range from formation damage to mechanical failure of completion equipment. This guide looks at the most ‘common methods used to monitor the cleanliness of the fluids in a well ~ It should be noted that clean fluid returns do not correspond to a clean well It may just be that the fluids are not removing the solids effectively. + After pumping the well clean-up chemicals, seawater or brine is normally circulated until certain criteria regarding cleanliness are met. + The criteria most commonly used are for Turbidity e.g. <100 NTU, measured by a Turbidity meter and/or Solids Content typically < 0.05%, which is measured using a centrifuge. - Turbidity measurements are quickly made, but are NOT directly related to ‘amount of solids. They are useful in identifying trends. ~ _ Solids measurement by centrifuge is more time consuming — at least 10 minutes, but are more accurate at determining the amount of solids in a fuuid + The solids are typically mud solids - clay, barte, mill scale/rust from the tubulars land fines from drilling the formation and cement. il from the mud may affect turbidity, but not total solids. ~ Some Companies use Rust in the retuming fluids as a sign that the clean-up has been effective and all the “oily mud” removed. Since the rust could come from e.g. only the high side of the well, with the low side still covered in oily ‘mud, this is not completely true.pendix 5 + Turbidity describes the relative clarity of a fluid. Put simply: dirty fluids are. cloudy, clean fluids are clear. Measurement of turbidity is one method where these contaminants can be detected. Fluids with a range of NTU values.Appendix 5 Turbidity Equipment Turbidity is measured using a turbidity meter with the result being displayed in nephelometer turbidity units (NTU). The lower the NTU, the clearer the fluid example of a turbidity meter rT + Turbidity meters work by measuring the amount of scattering of a light beam. A.cloudy fluid will scatter the light beam to a greater degree and give a high NTU reading, Conversely, a clean fluid will have 2 low NTU reading. The light source is normally a High Emission Infrared LED (Light Emitting Diode) with a wavelength of £90 nm. This frequency is used as it reduces the interference caused by coloured samples. (The darker the sample, the more absorption of the light). A sensor, positioned at 90° with respect to the direction of light, detects the amount of light scattered by the undissolved particles present in the sample. ‘A microprocessor converts these readings into NTU values.Roendix 5 Turbidity meters are made by a number of manufacturers. Hach and Hanna Instruments are two. The units for the rig site are small handheld devices normally powered by alkaline batteries. It is important that prior to use the unit has been calibrated against attest fluid (normally 10NTU). This is normally sourced from the instrument supplier. Instrument Range (Typical) 0.00 to 50.00 NTU @ an accuracy of #5% (0 to 10 NTU) & #10% (10-50 NTU) 50.00 to 1000 NTU @ an accuracy of 5% tors which can affect the test The following can interfere with the unit and give false readings + floating debris + coarse sediments which settle rapidly + oil droplets + strongly coloured dissolved substances + air bubbles 4 + vibration (affecting the surface of the sample) + dirty glassware especially scratched or etched vials used to hold the samples + sample pointAppendix 5 Section 2 Solids Measurement Another method of establishing fluid quality is by measurement of the un-dissolved solids content. This is normally achieved by use of a centrifuge. One difficulty with this method in the field is that there are @ number of differing centrifuge types which offer differing separation efficiencies, The small hand crank units usually found in offshore mud labs are significantly less accurate than electric units, due to the lower forces involved. Sample sizes range from 10 ml for small offshore centrifuges to 100 mI for an electric centrifuge usually found in a laboratory. Two samples of the fluid are taken and centrifuged for 10 minutes and the volume of the solids is recorded. Average the two results and quote the figure as % viv solids in the brine, The methodology is laid out in the Production Chemistry A.P.C.LA.M method for Task No PCT-245,Appendix 5 Solids Measurement Equipment The centrifuge type used in the Production Chemistry laboratory is an electric IEC - Damon Model HNS - Il, as shown below. Also shown is a centrifuge tube. Instrument Range (Typical) 4 0.025% to 100% for observable particles greater than 40 micron in size. Factors which can affect the test The following can interfere with the unit and give false readings: * centrifuge speed - a low speed can give false high or low readings + _ low density solids - may not settle out + crystalline solids which not be observable + coarse sediments which settle rapidly in the narrow bottom of the tube. + strongly coloured dissolved substances may interfere with the percentage reading * out of balance samples and tubes which may result in lower centrifuge speed + sample point + sample sizeAppendix 5 Helpful Facts For Turbidity and Solids Measurement Baselines (1) Pure clean freshwater has an NTU of 1 - § and below. (2) Unfiltered seawater has an NTU range of 2 - 8 (dependent on the source). (3) A typical oilfield NTU specification for a clean fluid would be <40 NTU's. (4) Set the NTU target appropriate for the operation. (5) For comparison, always check the turbidity of the completion fluid to be displaced into the well as well as the returning fluid (6) A Turbidity meter allows rapid analysis of returning well fluids. While a solids reading derived from a centrifuge is more accurate, it takes approximately 10 min to process each sample. (7) The use of turbidity measurement can detect light solids, cil and chemical Contamination, which might be missed if using a centrifuge and relying on solids content alone. (8) When brines are to be used as completion fluids, itis very likely that the desired cleanliness level would not be achieved in one circulation. For economic reasons filtration would be used on the returning fluid rather than simply discharging until the desired cleanliness level is achieved, (9) For inhibited freshwater and seawater completion fluids, filtration should stil be ‘considered ifthe extended circulating time/cost exceeds the rental and consumable filtration costs (10) The maximum insoluble solids content for a supplied completion fluid (brine) from a manufacturer is 0.025%. This fiqure was simply derived from the fact that this is the minimum detectable level that can be observed in a centrifuge tube! (11) A typical rig specification for the maximum solids level of a circulated completion fluid is 0.05%. This level can normally only be achieved by filtration if using brine. If using crillwater/seawater, then substantial dilution would be required with extended circulation times. ~ 1000 bbI of completion fluid containing the minimum observable level of solids(0.025% viv) would still contain 39.75 litres of solid matter!Appendix 5 Section(3) Filtration Why Filter ? Filtration is normally carried out on completion fluids where there is a danger that contaminants (solids) within the completion fluid could enter producing or injection points in reservoir formations leading to production impairment or loss Of injection efficiency. The pore throats of average North Sea wells can range in size from sub micron to >10 microns, ‘Another reason for filtering completion fluid is where deposited solids within the wellbore might adversely affect completion equipment function + Solids can be categorised into three size ranges: (1), Invading solids (2) Bridging solids (3) Plugging solids Invading Solids . * Solids that invade are those that are generally less than 15-20% the size of the permeable formation pore throats. Solids ofthis size will normally flow through without being trapped until the reducing fluid velocity allows the particle to settle. These solids will normally be back produced when the well is returned to production, Bridging Sc + Solids that bridge are within a size range between 20-50% the size of the pore throats. These solids will be trapped within the pore network very near the is wellbore and can cause significant permanent damage to the permeability of the formation. Since they are trapped within the pore network, itis difficult for this type of solids to be back-produced. In certain situations chemical treatments can assist in dissolving these solids and restoring permeabilityAppendix 5 Plugging Solids Solids that plug are larger than 50% of the size of the pore throats and will be deposited at the throat entrances building a filter cake. The largest particles will normally be back-produced however significant debris can build up on the face of the wellbore to seriously impair the formation. The decision to filter must be made according to the completion type: Geet Standard Standard Under balance No Excluder Screen NA Yes Injection Well Overbalance [Yes 7 | injection Well Under-balance Yes | Specifications the Nerth Sea to Shell Operations is that of a fluid having no concentration of suspended solids greater than 0.025% viv. * Inthe field usual practice has been to circulate or filter until the suspended fluids content is less than 0.05%, + The specification for turbidity is more complex. Normal practice has been to accept fluid clarity levels on completion fluid wellbore returns of 30-50 NTU. However many factors can affect NTU measurement- aeration, colour and oil content. + With NTU measurement, you must relate the NTU of the returned fluids to the NTU of fluid being pumped to the well. If relying on turbidity for deciding on the + The standard of cleanliness required of a supplied completion fui leanliness of your completion fluid, we would recommend that you calibrate the turbidity meter to the solids content of the fluid to be pumped to the well.Appendix 5 ~ The 0.025% viv retained solids standard has come about purely because 0.025% is the lowest reading that can be observed on the standard 100ml centrifuge tube and does not relate to a particular formation or standard permeability measurement + Notall formations will display the same characteristics. The level of cleanliness of the required completion fluid must be looked at on a well by well basis. For certain operations where completion fluid will only contact the formation in an under-balanced situation (time of perforation), filtration may be unnecessary. In an overbalance perforation, filtration would be considered essential. BRINE FILTRATION + Filtration is the usual technique to remove suspended solids from brines and completion fluids. Filtration technology has changed considerably from the 1980's when the primary filtration was almost exclusively carried out by passing the fluid through cartridges of woven cloth-type material (so-called sock’ fiters) or through wound fibre cartridges. + These "nominal" filters do not provide an “absolute” cut-off in particie size but merely an overall reduction in solids content is established. Filter medium characteristics are therefore classed as absolute or nominal. + The increased awareness in the industry of the importance of both the content and size distribution of suspended solids in workover and completion fluids on the performance of wells, has led to the introduction of more sophisticated fitration equipment. These are capable of providing an absolute cut-off in solids size, such as absolute cartridge filters and diatomaceous earth (DE) pre-coat fiters, ~ _ In preparation for brine filtration it is of paramount importance that all-surface and subsurface equipment (tanks, lines, pumps and downhole tubulars) are: ‘scrupulously cleaned to prevent brine contamination.