Summary A new water-based mud system was successfully introduced as a high-performance, environmentally compliant alternative to oil and synthetic emulsion-based muds (OBM/SBM). Historically, emulsion muds have been the systems of choice when drilling challenging onshore, continental shelf, and deepwater wells to minimize risk, maximize drilling performance, and reduce costs. However, environmental constraints, a high frequency of lost circulation, and the high unit cost of emulsion systems sometimes negate the benefits of their use. Conventional water-based muds (WBM) offer the benefits of environmental compliance, attractive logistics, and a relatively low unit cost but consistently fail to approach the drilling performance of OBM and SBM. The new high-performance, water-based mud (HPWBM) is designed to close the significant drilling performance gap between conventional WBM and emulsion-based mud systems. The system has undergone extensive field testing on very challenging onshore, deepwater, and continental shelf wells that would otherwise have been drilled with oil or synthetic-based muds. This paper provides a detailed, technical overview of the new system, discusses its inherent environmental advantages, and presents case histories comparing performance to offset wells drilled with emulsion and conventional WBM systems. Introduction The industry is increasingly drilling more technically challenging and difficult wells. Exploration and development operations have expanded globally as the economics of exploring and producing for oil and gas have improved with advancements in drilling technology. Advanced drilling operations such as deep shelf, extended reach, horizontal, and deepwater are technically challenging, inherently risky, and expensive. OBM and SBM have many inherent advantages over water-based drilling fluids, including temperature stability, tolerance to contamination, and corrosion protection. However, the fluid attributes of concern in this discussion are those most directly related to drilling performance and environmental issues. With consideration to reducing drilling problems such as torque and drag, stuck pipe, low rates-of-penetration, and wellbore stability, these wells are generally drilled with emulsion-based muds. Environmental legislation governing drilling waste is continually restricting the discharge limits of spent muds and drilled cuttings. Operators are challenged with achieving a balance between minimizing the potential environmental impact of the drilling fluid against drilling objectives. The inherent advantages provided by emulsion muds are increasingly being offset by environmental compliance restrictions.

Low density gas hydrate suppressive drilling fluids have been developed for deepwater applications. These fluids utilize low molecular weight organic compounds for gas hydrate inhibition. Fluid densities as low as 9. 11b/gal can be designed for fluids with gas hydrate suppression greater than 30 F relative to water. These fluids are especially suited for use when low fracture gradients are encountered while drilling intervals where gas hydrate formation in the drilling fluid is possible. In addition, these additives provide greater gas hydrate suppression to drilling fluids than that provided by conventional thermodynamic gas hydrate inhibitors. P. 201

One of the biggest challenges when drilling in deep water is the excessive dependence of drilling fluid rheological properties on temperature. Conventional drilling fluids often have high viscosity at the seabed temperature, which increases the Equivalent Circulating Density (ECD) and surge pressures when running pipe or initiating circulation, elevating the risk of fracturing the wellbore. This paper describes the development of a drilling fluid for deep-water applications, with minimum viscosity variation with temperature. Multiple laboratory formulations were evaluated during the development of the new, non-aqueous based drilling fluid that meets deep-water's challenging rheological and barite suspension requirements. CaCl2 brine was used as the internal emulsion phase, and synthetic isomerized olefin as the base oil. The testing followed the API Recommended Practice for Field Testing Oil-based Drilling Fluids. Samples were aged at dynamic conditions for 16 hours at several temperatures. Then, rheological properties and high-pressure high-temperature (HPHT) fluid loss, emulsion stability, and dynamic sagging were tested. Static sag experiments were also carried out for up to seven days together with improved step down rheology tests. A low-impact, non-aqueous drilling fluid (LIDF) was designed to minimize ECD increases by reducing the effect of cold temperature on the fluid viscosity. The fluid offers a superior low viscosity profile and rapid-set, easy-break gel strengths, while maintaining low shear rate viscosity at high temperatures with optimal weight material suspension. The fluid is also compatible with all contaminants usually found during the drilling operation and meets all the regulatory requirements for the Gulf of Mexico and other deep-water operational areas. Field application demonstrated that LIDF reduced the effect of temperature on the fluid rheological properties and minimized the risk of induced formation losses. These same rheological features reduced non-productive time associated with cement displacement and barite sagging. Supporting laboratory and field data are presented to demonstrate the superior performance of the fluid in maintaining rheological and barite suspension properties over a wide range of temperatures. The properties of the LIDF are achieved by matching the effects of emulsifier, organophilic clay, and rheological modifiers to maintain correct rheological properties at low and high temperatures.

fax 01-972-952-9435. AbstractA new water-based mud system has been successfully introduced as a high-performance, environmentally compliant alternative to oil and synthetic emulsion-based muds (OBM/SBM). Historically, emulsion muds have been the "systems-of-choice" when drilling challenging onshore, continental shelf and deepwater wells in order to minimize risk, maximize drilling performance and reduce costs. However, environmental constraints, a high frequency of lost circulation and the high unit cost of emulsion systems often negate the benefits of their use. Conventional water-based mud (WBM) offer the benefits of environmental compliance, attractive logistics and a relatively low unit cost but consistently fail to approach the drilling performance of OBM and SBM.The new high-performance water-based mud (HPWBM) is designed to close the significant drilling performance gap between conventional WBM and emulsion-based mud systems. The system has undergone extensive field testing on very challenging onshore, deepwater and continental shelf wells that would otherwise have been drilled with oil or synthetic-based muds.This paper provides a detailed technical overview of the new system, discusses its inherent environmental advantages and presents case histories comparing performance to offset wells drilled with emulsion and conventional WBM systems.

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