Mud types

General
Spud mud
Emulsion mud
 KCL Polymer mud
KCL PHPA mud
Glycol base mud
Silicate mud
Formate mud
High mud weight
Oil base mud
Mud engineering| Abdelaziz Gabr 3
 DRILLING FLUIDS SYSTEMS

Bentonite Spud Mud

• Requirements :
– High Viscosity (FV 100 sec+)
– Low Cost
– Hi-vis sweeps or circulating system
• Bentonite Spud Mud
– Requires fresh water to prehydrate Bentonite
– May be a circulating system or seawater - sweep system
 DRILLING FLUIDS SYSTEMS
Bentonite Spud Muds

• To mix prehydrated Bentonite (DRILL-GEL)

– Fill tanks with fresh water (chlorides less than 5000 mg/l)
– Add Soda ash to reduce total hardness to below 150 mg/l
– Add 0.5 - 1 ppb caustic soda to increase pH above 9.5
– Add 25 - 35 ppb API Bentonite
– Allow to hydrate at maximum shear for 6 hours if possible
• Dilute with water / sea-water (final Bentonite concentration = 15 -25 ppb)
• Add 0.2 ppb Lime just prior to pumping (sweep system only)
 Emulsion mud
• It is used incase pore pressure is lower than water column height .
• In case lost of circulation is expected
• The disadvantage of this mud is foaming
 composition
Material Unit Quantity(per bbl) Property Unit Value

Make-up Water Bbl 0.835 Density lb/ft3 62

Caustic Soda Lb 0.20-0.3 Funnel Viscosity sec/qt 45- 55
Bentonite Lb 10 pH 10
Starch Lb 4-6 API fluid loss ml 5-6
Diesel Bbl 0.15 PV cp ALAP
YP lb/100
Safe Surf Gal 0.05-0.1 ft² 24-30

XC-Polymer Lb 0.25 – 0.5

*IDCAP Lb 0.5-1
*KCl Lb 3.5 – 8.2
 Incase complete losses , switch to mud cap drilling

• High mud weight ( 2 ppg or 15 pcf ) more

than mud weight is pumped regularly from
annulus .
 DRILLING FLUIDS SYSTEMS

Non Dispersed Basic Polymer System

Additives
Density: Calcium Carbonate or Barite
Viscosity: Xanthan Gum
Fluid Loss: CMC LV, PAC LV, Starch
Inhibition: Gypsum, Lime, Salts, plus encapsulation with PAC

pH: Caustic or KOH

Bactericide: As required

Sometimes a little PHG is added instead of polymers to :

Give viscosity at a cheaper price and to provide plate-like material to
reduce initial fluid loss
 DRILLING FLUIDS SYSTEMS

Mixing Procedure

• Mixing order, add :

– Adjust pH of make-up water with caustic/KOH
– Fluid loss additives 15 min / sack (Low vis polymers first)
– XC- polymer , @ 15-20 min/sack (Viscosifiers)
– Gypsum / Lime / Salt (Inhibitive compounds)
– Bactericide
– Barite / Calcium Carbonate

• Minimize viscosifying polymer addition until after

displacement to minimize screen blinding.
• Add additional polymer as drilling proceeds.
 DRILLING FLUIDS SYSTEMS

Engineering Comments

• Displace to new mud system after drilling out cement.

• Effects of cement contamination will be worse in a fresh water system.
– Add sodium Bicarb or to treat it out

• Mud losses at the shakers are likely if coarse screens not fitted to start with
– Reduce circulation rates or use larger screens for 1-2 circulations

• Dump and dilute to maintain correct solids and MBT conc.

– Watch fluid properties for product depletion

• Add Xanthan to improve YP and low end rheology.

 DRILLING FLUIDS SYSTEMS

- KCl PHPA Polymer Systems

• Advantages
– Low Solids, inhibitive mud - better gauge hole
– Stabilizes shales by replacing sodium with potassium ion on exchange site
– PHPA’s minimize dispersion (via encapsulation)
– Increased solids removal efficiency

• Disadvantages
– Lubricity is not as good as NAF
– Possible Temperature limitations
– Bacterial degradation potential depending upon polymer.
– Generally not for high Ca++ environments
 HYDRO-FOIL GEN 1

PHPA Encapsulation

Mud pits and solids control:

PHPA in solution
 DRILLING FLUIDS SYSTEMS

Mixing Procedure

• Mixing order, add :

– Increase pH with KOH or caustic

– Fluid loss additives, 15 min / sack (Lo Vis polymers first)
– Viscosifiers @ 15-20 min/sack
– Potassium Chloride
– Barite / Calcium Carbonate
– Add the PHPA slowly at the suction pit

• Minimize polymer additions until after displacement to minimize screen blinding and
precipitation of polymer with Ca++
• Pretreat for cement contamination with Bicarb
 DRILLING FLUIDS SYSTEMS

Glycol system

A glycol-based drilling fluid system designed as an effective and environmentally safe

alternative to traditional oil and synthetic fluids for drilling troublesome shales.

Utilises cloud-point glycols, operating in conjunction with PHPA and other polymeric additives
to provide enhanced inhibition.

Basically this is an enhanced KCl/PHPA system which shows the flexibility of polymer systems

This is the most suitable mud system to be used in deep water drilling because it has very
important property called “HYDRATE SUPPRESION “ (GLY-DRILL SYSTEM)
 Polyglycol characteristics
• Polyglycol represent a family of chemicals that when dispersed in water, exhibit a
temperature related behavior that results in their ability to plug the pore channels of
shale bodies and there by minimize the entry of fluid.

• When the proper conditions are present, the Polyglycol can emerge from solution as a
cloud of microscopic droplets ( Thermally activated micro emulsion)

Cloud point of fluid: Temperature at which Polyglycol changes from being totally soluble
to insoluble.

This temperature varies with type of fluid and its ionic concentration.
 HYDRO-FOIL GEN 1
Visualisation of Polyol Behaviour as a Function of Temperature

Polyol and water together at Solution is heated until the polyol reaches “cloud
ambient temperature; the point” and becomes insoluble. A thermally
polyol is 100% water soluble activated micro emulsion forms
 HYDRO-FOIL GEN 1

Schematic of Cloud Point Activity for a Glycol Mud

Mud pits and solids control:

Glycol in solution
Temperature
reduction
lowers the
Glycol back
below its
cloud point
Downhole Glycol forms droplets or micelles
which coat out on wellbore and cuttings
 HYDRO-FOIL GEN 1
Visualisation of Polyol Behaviour as a Function of Temperature
 Deep water applications ( Gly-drill system)
• The DEEPWATER GLYDRIL system is used to drill reactive clay and shale
formations in water depths greater than 1000’ when hydrate
suppression is a major problem.
• This system uses NaCl and KCl salts, conventional polymers and glycol to
provide formation inhibition and hydrate suppression.
Deep water applications ( Gly-drill system)
Silicate mud
 Introduction
 Silicate enhanced systems are designed to drill very reactive shales.

 They strongly minimize shale hydration and improve formation integrity.

 They improve the efficiency of shale membrane for osmosis process.

 These systems can be used as an economic and environmental replacement for oil-
base muds.
 % Shale Recovery

50

0
10
20
30
40
60
70
80
90
100

FW/POLYMER

NaCl/PHPA

KCl/CaCl2/PAC

GLYCOL

GLYCOL/PHPA

GLYCOL
+ amine

GLYCOL 2

SILDRIL
Comparison between different types of mud

SILDRIL
+ GLYDRIL

SILDRIL
+ LUBRICANT

Oil-base mud
Cost / FT
350
Interval Cost/meter - US$

300

250

200

150

100

50

0
Dispersed KCl/PHPA KCl/Dispersed OBM SILDRIL-1 SILDRIL-2
 DRILLING FLUIDS SYSTEMS

SILICATES mud
Silicates system that utilises 5 – 15% v/v Sodium or Potassium Silicate solution to enhance
inhibition and mechanical wellbore stability, particularly in highly fractured or unconsolidated
formations.

The system pH is engineered to +/- 12 which has an adverse affect on certain polymer additives.

The system is formulated using most conventional polymers, with the exception of ENCAPSUL-8
(PHPA) Silicate enhanced systems are designed to drill very reactive shale

They strongly minimize shale hydration and improve formation integrity

 DRILLING FLUIDS SYSTEMS
SILICATES chemistry

• Soluble silicates are manufactured by the fusing of sand(SiO2) with sodium or

potassium carbonate (Na2CO3 or K2CO3) at 1100-1200°C.

• The resulting glass is dissolved with high-pressure steam to form a clear, slightly
viscous liquid that is sometimes referred to as “water glass”.
 DRILLING FLUIDS SYSTEMS
Mechanisms of wellbore stabilization by silicates

Gelation and Precipitation

1- Pore fluid pH is close to neutral (pH ~ 7) in almost all shales.
• When the oligomers (silicates solution) are diluted down to this neutral
pH, they may overcome their mutual repulsion and coagulate, forming 3D
gel networks.
• 2-In all shales pore fluids, there are free polyvalent ions present, (e.g.
Ca+2,Mg+2) that will instantaneously react with the oligomers to form
insoluble precipitates.
 DRILLING FLUIDS SYSTEMS
Mechanisms of wellbore stabilization by silicates

Gelation and Precipitation

• The gelled and/or precipitated silicates Provide a physical barrier that prevents
further mud filtrate invasion and pressure penetration.
• Thus, the wellbore and shale formation are effectively pressure isolated.

• Enhance the efficiency of the shale-mud membrane.

 SILICATE SYSTEM
Sealing of Microfractured Shales by Silicates
Inhibition Mechanisms of Silicates

H2O May Penetrate But Ions Are Excluded

Ca
Ca

H2O Ca Ca
SHALE PORE
Ca
Ca

~ GELLED/PRECIPITATED SILICATES
Silicate mud benefits
· Maximum penetration rates
· Minimal “bit balling” problems
· Caliper wellbore geometry for optimum cement jobs
· Excellent cuttings integrity for geology interpretation and for effective
removal by the solids control equipment.
· Low cost.
· High shale inhibition
Silicate mud limitations
• As a Drill-In Fluid?? (form gels & plug pore throats)
• Temperature Stability??
• Relatively Higher Coefficient of Friction than Conventional Water
Base Polymer Systems
• Drilling Calcium or Magnesium Salts.
Reservoir Drill in fluids

nd
Sa
e
tiv
uc
od
Pr
Reservoir
 DRILLING FLUIDS SYSTEMS

Drill-In Fluids

• Fluids used to construct wellbore in the producing formation.

• A drill-in fluid can be defined as a fluid that possesses the desirable properties of a good
drilling fluid but will also provide the necessary attributes of a completion fluid.

• Its primary attribute is the development of a filter cake which effectively prevents
formation damage and is easily removed
 DRILLING FLUIDS SYSTEMS

Drill-In Fluids
Drill-in fluids can be:

• Untreated mud held over from the previous section

• Treated mud held over from the previous section

• New fluid formulated specifically for the producing formation

Reservoir Drilling Fluid Design Criteria

Drilling Issues

• Good Drilling Properties:

Hole Cleaning
Lubricity
Low Fluid Loss (Bridging / FL additives)
Formation inhibition
Fluid compatibility with reservoir fluids
Environmental restrictions
Cost
- Bridging and Flowback Prediction

User-friendly software that combines Choosing PSD

accurate PSD information on “local”
grades of CaCO3 Abrahm’s rule D1/2

Histogram CaCO3

7.00%

CaCO3 (VF)
6.00%
CaCO3 (F)
CaCO3 (M)
5.00%

with Ideal Packing Theory to select

CaCO3 (C)
4.00%

3.00% optimum blend of bridging agents

2.00%
to bridge specific formation.
1.00%

0.00%
0.01 0.1 1 10 100 1000 10000
Particle Size Microns
 DRILLING FLUIDS SYSTEMS

Formate Systems

Recent Alternative to standard brine systems – NaCl, KCl, CaCl2

•Advantages
– Non damaging drilling in / completion fluid
– Also used for work over / packer fluids
– Temperature stability to 350°F and very resistant to contamination
– Suitable for slim hole drilling
– Non corrosive, Non toxic, Non scaling
•Disadvantages
– Cost, especially at high mud weights – Cesium Formate is extremely expensive
 DRILLING FLUIDS SYSTEMS
Basic properties of Formate Based Fluids
 DRILLING FLUIDS SYSTEMS

Formate Systems
• Additives

Density: - Potassium Formate (10.8 ppg saturated brine)

- Sodium Formate (13.1 ppg saturated brine)
- Cesium Formate (19.2 ppg saturated brine)
- Increase up to 2 ppg with CaCO3
Viscosity - Xanthan
Fluid Loss - PAC
Inhibition - Salts,

Bridging agents -CaCO3 150µ, Sized salts NaCl, etc.

 DRILLING FLUIDS SYSTEMS

Engineering Comments

• Do not use starch products with Formates

• Increase PH by using soda ash

• Do not retort at normal settings

– Formates decompose at 350°F
– Retort at 200°F

• Do not use Barite

– Formate systems solubilize barite giving toxic barium
 High mud weight ( more than 14 ppg )
• As additional solids (both desirable weight material and undesirable
low gravity drilled solids) are used into the mud to overcome pore
pressure, a special strategy and measurement should be considered
when handling such high density mud.
• Usually solids content vary from 40 – 46 % by volume
• PILOT TEST the mud in use once staring drilling new hole for density
increase limits and required formulation.

• Once final formulation is achieved, perform visual settling test with

 one sample static at ambient temperature for 12 hours
one sample heated in a closed HPHT cell at 270°F for 8 hours
 High mud weight ( more than 14 ppg )
• Make sure that you have enough space for the increase volume of added
Barite and needed water for dispersion to avoid pits flooding,
remember that each Barite bag (5000 lb) will increase the volume by
3.4 bbl and need another 3 bbl of water,
• Increasing volume= Total number of lbs / (S.G X 8.345 X 42)
 Mixing order
• Add initial volume of fresh water , then
make it up by Caustic soda & Soda ash.
• Add only (5 lb/bbl) bentonite for rheology
and then add (0.25 lb/bbl) viscosifier .
• Add FLR in fresh water also to get maximum
efficiency from it .
• Add lubricants, shale stabilizers to help in
mixing barite later
• Check viscosity above (40 sec/QT) , then
start adding barite until 110pcf
• After check Mwt=110 pcf , start adding
water for barite dispersion
 Mixing order
• Remember that each Barite bag (5000 lb)
will increase the volume by 3.4 bbl and need
another 3 bbl of water,
• Start adding thinners to disperse barite in
water , but keep in mind that thinners
dampens PH , so ( each 4 lbs of thinner
needs 1 lb of caustic soda ).
• Continue adding barite until Mwt= 150 pcf .
• Incase Mwt is more than 150 pcf, switch to
add Hematite or other weighting agents.

• Remember that keep adding water and

addition of thinners by pilot test while
running this mud to control solids and get
L.G.S less than 4%
 DRILLING FLUIDS SYSTEMS

Inverted Emulsion mud

• These fluids, because of their special nature of being a mixture of two immiscible liquids (oil and
water), require special treatments and testing procedures.
• Dispersed Phase: The liquid presents in the form of finely divided droplets.
• Continuous Phase: The liquid presents in the form of the matrix in which the droplets are
suspended.

• To keep these liquids stabilized (i.e. to keep the dispersed phase from coalescing and settling out of
the mixture), an emulsifier is added to form an interfacial film around the dispersed phase which
causes them to repel each other, so they remain dispersed.

• The effectiveness of an emulsifier depends on the alkalinity and electrolytes (chloride content) of the
water phase, and the temperature of the drilling fluid.
 DRILLING FLUIDS SYSTEMS
Invert Emulsion Systems – NON AQUEOUS FLUIDS (NAF)

•THREE PHASE SYSTEM

•Base Fluid - Diesel, Mineral Oil, Linear Paraffin, Internal Olefin, Esters – This is
the continuous phase,
•WATER – This is the internal phase – is in the form of emulsified droplets.
 All water soluble additives will be found in this phase (CaCl2, soluble lime)
•SOLIDS - barite, organophilic clays, drill solids, fluid loss control products,
LCM, etc.
All solids are surrounded by the continuous phase and are thus, oil-wet.
 DRILLING FLUIDS SYSTEMS
Emulsions

Internal Phase

Oil in water Brine in oil

Continuous Phase
 WATER
DROPLET

OIL
 Mixing procedures
• Two Mud pits are required to prepare OBM ( one for diesel & one for Brine)
• Diesel is added to first pit , and Fluid loss reducer is added
• primary emulsifier composed of two parts (Hydrophilic , Hydrophobic) …
 Hydrophilic part is attached to water brine and coat it well
 Hydrophobic part is attached to diesel , so the water droplets will be kept suspended in oil phase
• Lime is added to diesel mixture to make Saponiphication effect which helps eliminate interfacial
tension between oil, water and helps also in keeping alkalinity ,so acid gases can’t damage OBM.
• CaCl2 brine is transferred slowly from Water tank to Oil tank
• Viscosifier ( bentonite treated with amine ) is added slowly to the mixture while small hose of fresh
water is added on hopper .
• Secondary Emulsifier(Solid coating agent) is added to mixture which is composed of two parts
 First part is hydrophobic which is attached to oil phase
 Second part has adhesion force which attached to solid and coat it well , so it becomes oil wet
• Weighting agent is added to increase mud weight
 OIL BASE MUD PRODUCTS

Primary emulsifier
Have a hydrophilic polar head and an organophilic non-polar tail.
HYDROPHILIC HEAD
(WATER LOVING)

C C C C C O

C C C C C
OH
(OIL LOVING) ORGANOPHILIC TAIL
INSUFFICIENT EMULSIFIER CONCENTRATION

WATER WATER Wor

COALESCING st
DROPLET DROPLET
OF DROPLETS

ase
C
- Designed to Oil Wet solids

SOLID’S SURFACE
OIL BASE TESTING

ELECTRICAL STABILITY
METER
RETORT

• % SOLIDS
• % OIL
• % WATER

• OWR - Oil/Water Ratio

Invert Emulsion Calculated Data
• OIL / WATER RATIO (OWR)
• OIL Fraction = % Oil_(as a decimal) X (100)
% Oil + % Water

• WATER Fraction = (100) - (OIL Fraction)

• OIL Fraction / WATER Fraction = OWR

• Excess Lime (ppb lime) = POM X 1.295