It is a challenge to drill in highly deviated or horizontal holes with high differential pressures. Wellbore instability, differential sticking and mud loss are frequently encountered problems while drilling slanted wells in Kuwait across shale and sand series. Drilling became more challenging with considerable non-productive time. Therefore, it is necessary to identify a fluids solution when other options with casing zone isolation are not viable. Traditionally, oil-based mud (OBM) was used while drilling these formations with limited success. A customized fluid system was designed to overcome the issue of high overburden pressure in shale and sand series formations targeting effective bridging, minimizing pore pressure transmission, and strengthening the wellbore. A nano-size deformable synthetic polymer, along with sized calcium carbonate and graphite, was identified to effectively plug the pore throats and minimize fluid invasion, which was confirmed by particle plugging tests. A well section was identified to comingle the highly depleted and pressurized formations. This was the first attempt on a high-angle well with development drilling operations in Kuwait and was performed to facilitate the successful drilling of the reservoir. Traditional OBM was converted to a customized fluid system using a nano-size polymer and sized bridging additives based on proprietary software selection and a series of laboratory tests. Drilling and logging were successfully performed for the first time in the commingled section without incident. There was no wellbore instability or differential sticking tendencies, less torque and drag, as well as enhanced wellbore cleaning in the high-angle sections. This paper also presents some successful applications of the nano-size deformable polymer in OBM to drill highly depleted formations in HTHP wells managing up to 3500 psi overbalance across highly permeable formations.

Global energy demand has driven the petroleum industry to develop hydrocarbon resources from extremely harsh formations which contain ultra-high pressure and temperature (HPHT) reservoirs. Ultra-high density drilling fluids are critical to successful drilling and completion practices in all of these wells. In this paper, potential weighting materials were systematically evaluated and screened to accomplish an ultra-high density oil-based drilling fluid system (19.62 to 22.12lb/gal) aimed to utilize in ultra HPHT conditions (>30000psi and >410°F). Several potential high-density weighting materials were evaluated in the laboratory conditions. Basic properties (pure density, particle size/distribution, surface area etc.) were evaluated and compared. Special treatments were conducted to optimize the properties of weighting materials. HPHT filtration tests under static and dynamic conditions were conducted at higher than 410°F and 300 psi. Real cores with an average porosity of 19% and an average permeability of 50 mD were used in the filtration tests. Rheological properties, sag tendency, the volume of filtrate, and the filtrate cake characterization of oil-based drilling fluids were measured before and after heating at 410°F for 16 hours. Results revealed that ultra-micro manganese and ilmenite complex after suitable surface treatment could act as an ideal weighting material than ultra-pure barite or other materials, which could fail in rheology and sag controlling measurement with such high temperature and density. The viscosity and filtration analysis confirmed the stability and reliability of this novel ultra-high density oil-based drilling fluid. This study developed a challenged drilling fluid system under critical testing states, as well as established a systematical laboratory evaluation and screening procedure of weighting materials for ultra-deep wells and contributed recommendations on how to utilize it in the fields.

Summary Solids found in drilling fluids, particularly weighting materials, can cause significant formation damage by plugging of formation pores. This study investigates formation damage caused by using oil-based drilling fluid systems weighted by micronized ilmenite or micronized barite. Rheological properties of the oil-based-mud (OBM) systems were measured. High-pressure/high-temperature (HP/HT) static filtration experiments were conducted. A coreflood system was used to simulate dynamic conditions, allowing for drilling fluid circulation at the face of the core and measuring permeability damage. Computed-tomography (CT) scan analysis revealed formation damage and depth of solid invasion. The paper presents field applications of nondamaging micronized-ilmenite-based OBM, illustrating its advantages.

Global energy demand has driven petroleum industry to develop hydrocarbon resources from extremely harsh formations. Ultra-high density drilling fluids are critical to successful drilling and completion practices in all of these wells. In this paper, potential weighting materials were systematically evaluated and screened to accomplish an ultra-high density oil-based drilling fluid system (19.62 to 22.12lb/gal) aimed to utilize in ultra HPHT conditions (>30000psi and >410°F). Potential high-density weighting materials were evaluated. Properties (pure density, particle size/distribution, surface area etc.) were evaluated and compared. Special treatment was conducted to optimize properties of weighting materials. HPHT filtration tests under static and dynamic conditions were conducted at higher than 410°F and 300 psi. Real cores with an average porosity of 19% and an average permeability of 50 md were used in the filtration tests. Rheological properties, sag tendency, the volume of filtrate, and the filtrate cake characterization was measured before and after heating at 410°F for 16 hours. Results revealed that ultra-micro manganese and ilmenite complex after suitable surface treatment could act as an ideal weighting material than ultra-pure barite or other materials, which could fail in rheology and sag measurement with such high temperature and density. Viscosity and filtration analysis confirmed the stability and reliability of this novel ultra-high density oil-based drilling fluid. This study developed a challenged drilling fluid system under critical conditions, as well as established a systematical laboratory evaluation and screening procedure of weighting materials and contributed recommendations on how to utilize it in the fields.

It is a challenge to drill in highly deviated or horizontal holes with high differential pressures. Wellbore instability, differential sticking and mud loss are frequently encountered problems while drilling slanted wells in Kuwait across shale and sand series. Drilling became more challenging with considerable non-productive time. Therefore, it is necessary to identify a fluids solution when other options with casing zone isolation are not viable. Traditionally, oil-based mud (OBM) was used while drilling these formations with limited success. A customized fluid system was designed to overcome the issue of high overburden pressure in shale and sand series formations targeting effective bridging, minimizing pore pressure transmission, and strengthening the wellbore. A nano-size deformable synthetic polymer, along with sized calcium carbonate and graphite, was identified to effectively plug the pore throats and minimize fluid invasion, which was confirmed by particle plugging tests. A well section was identified to comingle the highly depleted and pressurized formations. This was the first attempt on a high-angle well with development drilling operations in Kuwait and was performed to facilitate the successful drilling of the reservoir. Traditional OBM was converted to a customized fluid system using a nano-size polymer and sized bridging additives based on proprietary software selection and a series of laboratory tests. Drilling and logging were successfully performed for the first time in the commingled section without incident. There was no wellbore instability or differential sticking tendencies, less torque and drag, as well as enhanced wellbore cleaning in the high-angle sections. This paper also presents some successful applications of the nano-size deformable polymer in OBM to drill highly depleted formations in HTHP wells managing up to 3500 psi overbalalnce across highly permeable formations.