section 11c

non aqueous drilling fluids

section 11c Scomi Oiltools

confi-drill 2
confi-dense 6
confi-deep 8
opta-vert 17
 Section

11c non aqueous drilling fluids

non aqueous drilling fluids

confi-drill
CONFI-DRILL is an invert emulsion drilling fluid system which can be tailored to meet environmental
and performance criteria. The system has excellent rheological and filtration characteristics easily
modified to meet changing pressure and temperature conditions,

The system consists of three phases; non aqueous, brine and solid.

The key to the system is the emulsifying chemicals designed to create and maintain the invert emulsion.
The system can be formulated with a range of base fluids including low toxic mineral oil (LMO), linear
paraffin (LP), linear alpha olefin (LAO) and internal olefin (IO).

Mechanism of Shale Stabilisation

Invert emulsion drilling fluids provide the highest level of shale inhibition by a drilling fluid. An invert
emulsion consists of two liquid phases:-

ƒ A hydrophilic brine internal phase.

ƒ A hydrophobic non polar continuous phase.

The internal phase is emulsified into the continuous phase with the use of emulsifiers.

As the hydrophobic continuous phase will not solvate or swell exposed shales, it makes the fluid system
ideal for drilling hydratable shales.

This characteristic is the basis for the use invert emulsions as non-reactive, inert drilling fluids. As water
contamination of the drilling fluid is unavoidable from drilled formation, the drilling fluid system must be
formulated to tolerate this additional water.

To prevent the internal hydrophilic phase from reacting with the formations, the system is formulated
with high salinity brine, usually calcium chloride. If the salinity of the brine is maintained at a
concentration higher than the formation salinity, water will flow by a process of reverse osmosis from
the formation into the fluid, stabilising reactive formations.

Benefits of the invert emulsion system include:-

ƒ Inhibition ƒ Fluid properties are tolerant of solids
ƒ Low filter loss ƒ Resistant to contamination
ƒ Re-use ƒ Protection against corrosion
ƒ Can be engineered to any specific requirement ƒ Low dilution rates
ƒ Thin, slick filter cake ƒ Can be formulated to relatively low densities
ƒ Can be engineered with environmentally ƒ Highly lubricious
friendly base fluids
ƒ Simple to use

The advantages of the system must be considered along with the limitations:-

ƒ High cost of losses ƒ Cost of remediation

ƒ High initial make up costs ƒ Re use may lead to build up of low
ƒ May have environmental restrictions gravity solids
ƒ May require complex clean up procedures


Formulation
An example of a CONFI-DRILL formulation and associated properties is detailed in Table 1. It must be
highlighted that product concentration will vary depending not only due to the density, temperature
and product ratio’s but also with the type of base oil utilised.

Product Function Concentration Concentration

lb/bbl kg/m3
Base Fluid Base fluid 0.68 bbl/bbl 0.68 m3/m3
CONFI-MUL P Primary emulsifier 6 17.1
CONFI-MUL S Secondary emulsifier 2.5 7.1
CONFI-GEL HT Viscosifier 6 17.1
CONFI-MOD Rheology modifier 1 2.85
CONFI-TROL / Filtration controller 2-8 5.7 - 22.8
CONFI-TROL HT
drillwater Liquid phase 0.175 bbl/bbl 0.175 m3/m3
calcium chloride Water phase salinity 22 62.7
lime Emulsifier activator 8 22.8
DRILL-BAR Weight material 120 342

Table 1. Example CONFI-DRILL formulation

Property Typical Value Units

Mud Weight 9.5 lb/gal
PV 15 cP
YP 12 lbs/100 ft2
6 rpm 8 dial reading
10 minute Gel 10 lbs/100 ft2
HTHP (@ 250 °F) 2.0 ml /30 min

Table 2. Example CONFI-DRILL properties

In addition to the basic products supplementary products can be used to optimise the system for
specific use. These supplementary products and their function and concentration are listed in Table 3.

Product Function Concentration Concentration

lb/bbl kg/m3
CONFI-COAT Oil wetting agent 0.5 - 2 1.4 – 5.7
CONFI-LUBE Lubricant for SBM 1–3 1 – 3%
CONFI-PLEX LSR modifier 1–3 2.85 – 8.55
CONFI-THIN Oil wetting agent 0.5 - 2 1.4 – 5.7
CONFI-TROL Solid fluid loss control additive 2–8 5.7 -22.8
CONFI-TROL F Liquid fluid loss control 1–5 2.85 – 14.25
additive
CONFI-WET Oil wetting agent 0.5 - 2 1.4 – 5.7

Table 3. Supplementary products for CONFI-DRILL systems


 Section

11c non aqueous drilling fluids

Engineering Guidelines
In general the following guidelines and mixing procedures apply to all non-aqueous fluids except where
indicated in system specific sections of this handbook.

Mixing CONFI-DRILL
When mixing an invert emulsion system the amount of shear in the mixing system has to be maximised.
It is recommended that a shearing unit is used and the fluid shear is maximised by circulating through
the gun lines.

1. Add the required quantity of base fluid to the mixing tank.

2. Add the primary emulsifier, CONFI-MUL P, and secondary emulsifier, CONFI-MUL S, as required.
3. Add organophilic viscosifier, CONFI-GEL / CONFI-GEL HT, as required.
4. Add required amount of water to the above mixture. If brine is to be used, then add brine after
the lime additions.
5. Add rheology modifier e.g. CONFI-MOD or CONFI-RM as required.
6. Add lime as required.
7. Add filtration control additives, CONFI-TROL, CONFI-TROL HT, CONFI-SEAL or or CONFI-TROL F,
as required.
8. Add calcium chloride powder if brine is not used. If calcium chloride powder is not available, then
mix the calcium chloride flakes into the water and add as a brine.
9. Mix above for several hours to ensure a good emulsion is formed.
10. Add weighting material as required for the desired density.

The shear available on most rigs is rarely sufficient to ensure that the organophilic clays have fully
yielded. Once the fluid is sheared through the bit, and heated, the rheology profile should increase.

Emulsifier
Emulsifier ensures that the invert emulsion is stabilised and provides initial filtration control with
zero water breakthrough. The measurement of emulsion stability gives an indication of the condition of
the emulsion. Optimisation of the emulsifier concentration will ensure that there is good temperature
stability, stabilised rheology and optimised lubricity.

Filter Loss
Filtration controllers are used to maintain filtration control. They act in conjunction with the emulsifier
package. Scomi Oiltools have a proprietary family of powdered filtration controllers including,
CONFI-TROL and CONFI-TROL HT as well as a liquid product, CONFI-TROL F, specifically formulated to
act synergistically with the emulsifier package. The effect of these products is specific to the emulsifier,
oil water ratio, temperature of test, density of the fluid and type of base fluid.

It is recommended that the HPHT filtration test is run at 25 ˚F (14 ˚C) higher than the maximum expected
bottom hole temperature.

Density
DRILL-BAR is used to provide density. If higher densities or flatter rheological profiles are required then
HyPR-BAR, fine grind barite, HAEMATITE or HYDRO-MAX can be used in the formulation.

In some cases additional density may be achieved by replacing the calcium chloride brine with calcium
or sodium bromide brine or by maintaining lower oil: brine ratios using either calcium chloride or
alternatives including sodium formate, in particular where a low solids content of the fluid is required.


Rheology
It must be highlighted that while drilling ahead there will be an increase in rheology as the
organophilic clay yields. This is particularly true when new fresh mud is delivered to or mixed on the rig.
Ensure that this increase in rheology does not become an operational problem, it must be controlled.

The two principal methods of imparting rheology are the use of the Organophilic clay, CONFI-GEL/
CONFI-GEL HT and or low end rheological modifiers. Optimise the effectiveness of organophilic
clays, with the addition of CONFI-MOD and/or CONFI-RM. The use of these modifiers will provide a
flatter rheology profile minimising the ECD. Note that overuse of rheology modifiers without sufficient
underlying organophilic clay structure can promote barite sag, which is detailed in section 6b of this
handbook, barite sag.

Oil Wetting Agents

The use of oil wetting agents, CONFI-WET and thinners, CONFI-COAT, should be avoided as the
difference between product effectiveness and over treatment can be a very fine balance. The thinners
act on the organophilic agents and destroy their effectiveness. Once a system is over treated it
becomes difficult to re gain the rheology and the danger of sag becomes more pronounced. If a
treatment of oil wetting agents is to be made to the circulating system, it is advisable that the
treatment is pilot tested extensively beforehand to determine the correct treatment level.

Lime
Lime is required to activate the emulsifiers; therefore, it is imperative the lime concentration be
maintained in excess as the efficacy of the emulsifiers is optimised. Experience demonstrates while
drilling ahead the excess lime concentration is steadily depleted. This is particularly noticeable while
drilling reservoir sections and or higher temperature zones. Lime will also be removed by acid gases.

Water Phase Salinity

The activity coefficient of the water, or brine phase, Aw, should be maintained lower than the activity
of the formation fluids. The water phase salinity ensures that the drilling fluid exerts a reverse
osmotic pressure on the formation, the activity level being determined by the type and concentration
of the salt.

The Aw is maintained with a salt most commonly calcium chloride. The determining factor for the
concentration of salt used is the status of the shale cuttings which should be firm and discrete. Any
sign of hydration of cuttings indicates that the water phase salinity level must be increased.

For reservoir drilling the brine phase may be provided by alternative salts including sodium bromide,
sodium formate and calcium bromide.

Temperature
A characteristic of invert emulsion systems is high temperature stability. The limiting factors being
the effectiveness of the emulsifiers, viscosifiers, rheological modifiers and filtration control, agents
at the elevated temperature. At elevated temperatures there will be a more rapid depletion of the
emulsifiers. This will also vary with density and type of base fluid.

Cementing
The primary effects of cement contamination are increases in the excess lime and water contents.

However the pre-flush pills used prior to cementing are designed to change the wettability of surfaces
which they achieve by attacking the emulsion package of the fluid. To minimise contamination of
the drilling fluid the volume of preflush pills should be minimised. Contamination of the mud by
the preflush results in a fall in emulsion stability, an increase in the HPHT filtrate and a decrease in the
base fluid/brine ratio. This contamination may be treated by increasing the oil/brine ratio with an
base fluid rich premix that contains an excess of emulsifiers.


 Section

11c non aqueous drilling fluids

If possible any excess pre flush that reaches surface should be isolated from the system on the first
circulation, though in most cases it is so entrained into the mud it is impossible to isolate. When
cementing liners, however, the excess cement and preflush may be reversed out and it should be
possible to readily isolate the contamination in this case.

Solids Control Equipment

During displacements or after a trip, the shakers should be dressed with relatively coarse screens.
The size of the screen should be reduced as the fluid warms up and the viscosity of the mud decreases.

Gas Solubility
Gas is soluble in NAF which has major consequences for well control as gas will stay in solution until
close to surface and for deepwater wells expansion may not occur until the influx is in the riser. Kick
detection may be severely compromised and the ability to detect and react to very minor volume
changes is highly significant. This is especially true for H2S which is 40 times more soluble than
methane.

It should also be noted that solution gas, including trip gas, will be detected, in decreasing quantity,
at the same spot in the circulating system for several circulations until it is finally released from the mud.

Gas solubility is a function of temperature and pressure and will vary with base fluid type e.g. internal
olefins and mineral oils the response of both base fluids is similar to 4,000 psi. Above 4,000 psi
(27579 kPa) the effects of pressure dominate the solubility for mineral oils with methane being
completely miscible above 7,000 psi (48263 kPa) and effects of temperature are not significant.

On the other hand temperature has a pronounced affect on gas miscibility in internal olefins above
4,000 psi, higher temperatures significantly reducing the pressure at which methane is fully miscible,
from + 11,000 psi at 150 ˚F to + 8,500 psi at 300 ˚F (+ 75800 kPa at 65 ˚C to + 58600 kPa at 149 ˚C )

If condensate is either present or the main component of a ‘kick’ there may be differences in behaviour
compared to methane alone in solution:

1. Kick detection may be delayed for condensate kicks relative to methane kicks.
2. As the kick / base fluid mixture becomes heavier there is a corresponding decrease in volatility and
bubblepoint pressure, i.e. rapid expansion happens closer to surface.
3. Significant expansion of a kick occurs nearer to surface for ondensates than for methane and,
when it does occur because of gas evolution, it is more rapid. The rise in surface pressure shows
the same trend. The heavier the condensate and, for SBM, the lower the concentration, the nearer
the surface the rapid expansion and pressure rise occur as the bubblepoint pressure is lower.
4. When a condensate kick occurs in SBM contamination of the mud with condensate occurs as
only the volatile components are released at surface. This may have consequences for discharge
and or disposal of contaminated mud.

confi-dense
System Description
CONFI-DENSE is base oil or synthetic fluid based drilling fluid specifically engineered to provide
emulsion stability for high density and high temperature applications beyond the range of the
standard CONFI-DRILL system. The CONFI-DENSE system is stable to temperatures in excess of 400 ˚F
(204 ˚C), exhibiting minimal density differentiation under both dynamic and static conditions. The
system can be weighted to above 18.5 lb/gal (2.22 SG) with barite, or alternative weight materials such as
HAEMATITE and is run with higher Oil:Brine ratios of 85/15 to 90/10+. The system has excellent
rheological and filtration characteristics which are easily modified to meet changing pressure and
temperature conditions.


Formulation
An example of a CONFI-DENSE formulation and properties is detailed in Tables 4 and 5

Product Function Concentration Concentration

lb/bbl kg/m3
Base Fluid – Iso Base fluid 0.48 bbl/bbl 0.48 m3/m3
Paraffin
CONFI-MUL HT Primary emulsifier 4-6 11.4 – 17.1
CONFI-GEL HT Viscosifier 2-4 5.7 – 11.4
CONFI-TROL F Filtration controller 5-6 14.25 – 17.1
CONFI- TROL HT Filtration controller 4-8 11.4 – 22.8
calcium chloride Water phase salinity 7 20
Drillwater 0.05 bbl/bbl 0.05 m3/m3
lime Emulsifier activator 10 18.5
DRILL-BAR Weighting agent 493 1405

Table 4. Example CONFI-DENSE formulation

Property Typical Value Units

Mud Weight 17.5 lb/gal
2.10 SG
PV 49 cP
YP 18 lbs/100 ft2
6 rpm 8 Dial reading
OWR 90:10
ES 1655 volts
Excess Lime 4 lb/bbl
HTHP (@ 350 °F) <2.0 ml/ 30 min

Table 5. Example CONFI-Dense properties

In addition to the basic products supplementary products can be used to optimise the system for
specific use. These supplementary products and their function and concentration are listed below

Product Function Concentration Concentration

lb/bbl kg/m3
CONFI-TROL XHT HT fluid loss control 1-4 2.85 – 11.4
CONFI-GEL XHT HT viscosifier 1-4 2.85 -11.4
HyPR-BAR Fine grind barite As required As required

Table 6. Supplementary products for CONFI-DENSE systems

A number of key aspects of the CONFI-DENSE system are;

ƒ Both polymeric and organophilic clay viscosifiers are used to provide optimum rheology with a
high base fluid:brine ratio.
ƒ Formulations are engineered specifically to each project.
ƒ Several filtration control additives are used to ensure the efficacy of the system at elevated temperature.
ƒ The system is formulated such that the parameters are independent of base oil type.
ƒ Due to the high solids content the system requires higher base fluid:brine ratios.

Engineering Guidelines
See guidelines under CONFI-DRILL.


 Section

11c non aqueous drilling fluids

Pressure and Temperature Effects for HTHP fluids

Drilling fluid density and rheology are functions of temperature and pressure encountered in the
well. Higher pressures will increase rheology and density; higher temperatures will decrease them.

Note: The temperature effects on NAF are much higher than WBM as base oils have a much lower specific
heat capacity and lower thermal conductivity than water.

Fann 35 rheology readings at surface conditions do not reflect the rheology of the fluid at elevated
pressures and pressures therefore it is very important to regularly run the rheology on a Fann 75
and measure the rheology at bottom hole conditions. Rheological modelling, e.g. ECD calculations,
using only Fann 35 data will be inaccurate.

The volume of the fluid will increase and decrease while drilling and tripping as the fluid heats
and cools. This normal volume variation can lead to the interpretation that the well is flowing or losing.
To fully establish the effects of pressure and temperature and establish a ‘fingerprint’ of the fluid
behaviour to provide information to distinguish between “normal losses”, “down hole losses”, or “gains”
the following steps should be taken.

When the mud has reached equilibrium operating temperatures for each interval establish and record
the normal changes in surface volume due to:-

1. operation / shut down of mud pumps,

2. Running mud pumps at different rates,
3. Operation / shut down of mix pumps and solids control equipment.

Mud Coolers
To lower both the surface and downhole circulating temperatures a mud cooler may frequently be
used on HTHP wells. This surface cooling can lead to a reduction of > 25 - 50 ˚F (14 - 28 ˚C) plus in the
maximum flowline and circulating downhole temperature. This is of particular benefit for extending the
range and life of downhole tools.

confi-deep
CONFI-DEEP is a flat rheology invert emulsion drilling fluid system designed and formulated for
application in deep water drilling.

HSE: The CONFI-DEEP system is handled in the same way as any other non aqueous system. Always refer
to the MSDS of the base oil and the individual additives for safe handling instructions.

In deep water environments, a seawater temperature of 39 °F (4 ˚C) is typically measured. The

formation temperature may range to 212 °F (100 ˚C) or more. This variation in temperature causes wide
fluctuation of rheological properties in conventional invert emulsion drilling fluids which leads to:

ƒ pressure spikes
ƒ induced fractures with “wellbore ballooning/breathing”
ƒ barite sag
ƒ poor cuttings suspension
ƒ reduced hole cleaning
ƒ excessive ECD
ƒ severe mud losses
ƒ cuttings pack-off leading to stuck pipe
ƒ reduced drilling efficiency


The problem is compounded when pore pressure and fracture gradient converge. The margin for
density fluctuations is low or non-existent. Strict control of the ECD is required to prevent fracture
induction and often extremely expensive mud losses.

A comprehensive investigation of the complex and interactive chemistry of surface active agents
including emulsifiers; wetting agents and novel polymeric rheological modifiers to formulate a fluid
system with remarkably constant rheological properties over a broad temperature range has been
undertaken. Development was and continues to be focused on reducing the organophilic clay content
and balancing hole cleaning, suspension requirements using special rheology modifiers to deliver a
fluid with cold water viscosity values 33 – 50% of those of a conventional invert system

The result is the flat rheology CONFI-DEEP system which delivers a consistent rheological profile over
a wide range of temperatures, 40 - 200+ °F (4 - 95 °C) with ongoing development work demonstrating
the potential of the system to perform at temperatures up to 250 °F (121 °C). Flat rheology of these
deepwater systems typically considers plastic viscosity, yield point, and 6 rpm values.

Each application is rigorously pilot tested in the lab to assure conformance of design to ECD
requirements established by very detailed hydraulic modelling.

Figure 1 compares the yield point and 6 rpm values of CONFI-DEEP with a typical non aqueous fluid.
YP (Ib/100ft2) / 6 rpm reading

Figure 1 Rheology of CONFI-DEEP

CONFI-DEEP system is surprisingly tolerant of solids, water and oil contamination. While the
rheological properties change with contaminant concentration, the fluid remains stable and very
resistant to water wetting of solids. Rheological properties remain flat despite high concentrations
of contaminants. Incorporation of drill solids actually improves system properties and performance


 Section

11c non aqueous drilling fluids

CONFI-DEEP can be formulated using wide variety of base oils providing the same level of flexibility
as with any other conventional non aqueous system currently in use in deep water drilling:

ƒ low toxic mineral oil

ƒ linear paraffin
ƒ linear alpha olefin
ƒ internal olefin

Conversion Flexibility and System Stability

The standard invert emulsion system CONFI-DRILL may be converted to the CONFI-DEEP system, but
only after thorough pilot testing. Conversion of salvaged mud offers potential cost savings and in some
cases a more stable and flat “pre-aged” mud system. The conversion process and the treatment have
been verified in the laboratory using a variety of salvaged mud systems mixed in 33 – 50% proportions.
Extensive lab tests also have confirmed the ability of CONFI-DEEP to incorporate surprisingly large
quantities of drilled solids, seawater, and cement as illustrated in Figure 2.

F ig ure 2 : C O N F I -DEE P S yst em S tab ility

(after hot roll @ 2 0 0 F for 16 hours)
40

35

30

25
YP (Ib/100ft2)

20

15

C O N F I -D E E P + 4 0 p p b r e v d u s t
10
C O N F I -D E E P + 2 5 p p b r e v d u s t + 5 p p b c e m e n t
5 C O N F I -D E E P + 2 5 p p b r e v d u s t + 2 0 % ( v /v ) s e a w a t e r

40 F 70 F 120 F 150 F
Temp (deg F)

Figure 2 CONFI-DEEP contamination tolerance

10
Performance:

ƒ Stable Rheology over wide ƒ Decreased pack off chances

range of temperatures ƒ Less dilution required
ƒ Pressure spikes minimised ƒ Can be converted from CONFI-DRILL system
ƒ Carrying & Suspension capacity increased ƒ Can be formulated using variety of base oil
ƒ Decreased barite sagging tendencies

Advantages:

ƒ Improved ECD management ƒ Less chances of stuck pipe

ƒ Reduced fracture induction ƒ Flexible formulation
ƒ Reduced losses ƒ Reduced environmental cost
ƒ Less chances of formation breathing ƒ Lower overall well cost
ƒ Better hole cleaning ƒ Optimized drilling performance

The CONFI-DEEP system, similar to other invert emulsions, consists of three phases, two immiscible
liquids, base oil and brine, and the third, a solids phase of barite and drilled solids.

CONFI-DEEP products

Pilot testing at the wellsite, with these products, is strongly advised for assuring economical and
effective treatment levels

Base Fluid
As noted previously a wide selection of base fluids may be used to build a CONFI-DEEP system, however,
as is the case with any system for low temperature applications a base fluid with a pour point lower
than the expected sea bed temperature must be used to avoid mud solidification.

Brine
Calcium chloride, CaCl2, is the salt of choice to be used for lowering the mud activity to balance shale
activity. CaCl2 is used to ensure Aw as close to that of the clay/shale or lower.

cDEEP-MUL
A specially engineered surface active emulsifier and wetting agent in the CONFI-DEEP system is based
upon complex surfactant chemistry, cDEEP-MUL emulsifies the brine in the base fluid and maintains an
oil wet state of drilled solids, barite, and other solids. Other functions of cDEEP-MUL include
deflocculation of system components and rheological control and stability. cDEEP-MUL also provides
very effective HPHT fluid loss control up to about 200 °F (93 °C), reducing the requirement for fluid loss
agents.

cDEEP-MUL provides stable and tight emulsion over a wide temperature range from 32 – 250 °F
(0 - 120 °C). The cDEEP-MUL concentration is custom optimised for each field application to provide
stable rheology and fluid loss over the temperature range specific to the well.

CONFI-MUL SA
A blend of saturated fatty acids used in non-aqueous fluids to increase viscosity and provide
support for weight materials particularly for freshly mixed muds during transportation as the full
viscosity of the fluid is dependent on heat and shear in the wellbore along with solids incorporation.
When exposed to higher temperatures in the wellbore CONFI-MUL SA liquefies, the initial temporary
viscosity is lost, and the product and works as a weak secondary emulsifier. Its primary function is
to provide suspension characteristics to freshly prepared mud before the viscosifiers have fully yielded.

11
 Section

11c non aqueous drilling fluids

cDEEP-MOD
Is a specially designed organic polymer designed to maintain a flat rheological profile over the full
range of temperatures encountered in a deepwater well. cDEEP-MOD is the primary viscosifier of the
CONFI-DEEP system at temperatures > 68 °F (20 °C).

cDEEP-RM
Is a secondary modifier to assist in maintaining a flat rheology profile while drilling. An engineered
combination of a special organic polymer and rheology modifier provides a stable dynamic flow profile.

CONFI-GEL HT
Premium organophilic clay which may be used as a supplementary viscosifier in the CONFI-DEEP
system to provide additional gel structure to minimise sag. CONFI-GEL HT primarily provides
rheological control below about 68 °F (20 °C) when used at low concentration. CONFI-GEL HT also is an
effective emulsifier of water into non-aqueous fluids and a fluid loss reducer.

cDEEP-TROL
Is the primary fluid loss control additive for the CONFI-DEEP system. The additive has a synergistic
effect with the system emulsifiers in controlling and reducing the HPHT fluid loss.

Other non aqueous fluid loss additives may also be used but should be pilot tested before addition.
The effectiveness of different fluid loss control additives is dependent on OWR; temperature, density
and the type of base oil. Laboratory tests are advised for ascertaining the correct formulation for the
project.

cDEEP-BAR
Is an economical non API sub-400 mesh barite for use in deepwater operations. cDEEP-BAR typically
exceeds API quality specifications for mineral quality. cDEEP-BAR is specifically ground for formulation
and maintenance of drilling fluids in which ‘barite sag’ is virtually eliminated in all fluid types and
densities. cDEEP-BAR is a solution for fracture induction losses due to a narrow mud weight window.
The products inherently low contribution to viscosity supports use in ECD sensitive wells.

cDEEP-THIN
A specially formulated and engineered complex surfactant polymer used in low concentrations as a
thinner for the CONFI-DEEP system. It is very powerful and must be used carefully and judiciously –
again pilot testing must take place before addition of ANY quantity. Overtreatment of any non-
aqueous fluid with a thinner, can result in a serious deterioration of fluid properties which may be
expensive to correct.

Lime is required for activation of the emulsifiers and proper solubilisation of cDEEP-MOD. Extensive
studies have determined that the EXCESS lime content must be maintained greater than 3 lb/bbl
AT ALL TIMES

12
CONFI-DEEP formulations

General formulation

Product Function Concentration Concentration

lb/bbl kg/m3
base fluid Continuous phase of emulsion As required As required
cDEEP-MUL Primary emulsifier and wetting agent 7 - 13 20 - 37
CONFI-MUL SA Suspension for fresh mud 1–3 2.85 – 8.55
cDEEP-MOD Primary viscosifier – flat rheology 1.5 – 3 4.3 – 8.55
additive
cDEEP-TROL Filtration control 2–5 5.7 - 14
CDEEP RM Secondary modifier As required – pilot As required – pilot
test test
CONFI-GEL HT Secondary viscosifier 0–4 0 – 11.4
cDEEP-THIN Thinner – rheology control < 0.5 < 1.4
(as required) (as required)
lime Alkalinity 8 22.8
CaCl2 Water phase activity, Aw As required As required
DRILL-BAR Density As required As required

Table 7 General Formulation

Example CONFI-DEEP formulations (by density and SWR) with Saraline 185V

Density – lb/gal 7.9 9.0 10.5 15.0

Products
cDEEP-MUL – lb/bbl 13 13 13 13
cDEEP-MOD – lb/bbl 2 2 2 1
CONFI-GEL HT– lb/bbl 3 2 1.5 1
cDEEP-MUL SA – lb/bbl As required As required As required As required
lime – lb/bbl 8 8 8 8
95% CaCl2 - lb/bbl 36 34 35 22
DRILL-BAR 61 153 394
Fluid Properties
OWR 70/30 70/30 75/25 75/25
Rheology at 150 °F
PV – cP 13 13 16 22
2
YP - lb/100 ft 20 20 16 25
6 rpm 13 12 12 15
HTHP filtrate, ml <4 <4 <4 <4

Table 8 CONFI-DEEP formulations (Product concentrations lb/bbl will vary with base fluid selection)

13
 Section

11c non aqueous drilling fluids

Example CONFI-DEEP formulations (by density and SWR) with Saraline 185V

Density - SG 0.95 9.0 1.26 1.80

Products
cDEEP-MUL – kg/m3 37 37 37 37
cDEEP-MOD – kg/m3 5.7 5.7 5.7 2.85
CONFI-GEL HT– kg/m3 8.55 5.7 4.3 2.85
cDEEP-MUL SA – lb/bbl As required As required As required As required
lime – lb/bbl 22.8 22.8 22.8 22.8
95% CaCl2 - lb/bbl 103 97 100 63
DRILL-BAR 174 436 1123
Fluid Properties
OWR 70/30 70/30 75/25 75/25
Rheology at 150 °F
PV – cP 13 13 16 22
2
YP - lb/100 ft 20 20 16 25
6 rpm 13 12 12 15
HTHP filtrate, ml <4 <4 <4 <4

Table 9 CONFI-DEEP formulations (Product concentrations kg/m3 will vary with base fluid selection)

The following graphs, figure 3 plot the rheology of different fluid densities vs. temperature

CONFI-DEEP - Yield Point graph

30

25
YP, Ib/100ft2

20

15

10 7 .9 p p g ( s o lid f r e e )

9 ppg

1 0 .5 p p g
5
15 ppg

0
40 F 70 F 120 F 150 F

Temp, deg F

CONFI-DEEP - 6 rpm graph

20

16
6-rpm, DR

12

8
7 .9 p p g ( s o lid f r e e )

9 ppg
4 1 0 .5 p p g

15 p pg

0
40 F 70 F 120 F 150 F

Temp, deg F

14
 CONFI-DEEP -PV graph
90
80
70
60 7 .9 p p g ( s o lid f r e e )

PV, cP 50
9 p pg

1 0 .5 p p g

40 15 p pg

30
20
10
0
40 F 70 1
F20 F 150 F

Temp, degF
Figure 3 Rheology vs. Temperature and pressure

CONFI-DEEP mixing procedure:

ƒ Add the required amount of base fluid in the mixing tank.

ƒ Add cDEEP-MUL to the base fluid at the required dosage.
ƒ Mix cDEEP-MOD slowly in the mixing tank and shear thoroughly for proper dispersion to get
viscosity. The use of a shearing device is recommended.
ƒ Mix CONFI-GEL HT if required and continue shearing. Shearing is very important for viscosifiers to
yield.
ƒ Add lime
ƒ Add prepared brine of the required salt concentration to the mixing tank. If brine is not available,
bleed in water slowly running the hopper continuously while bleeding in the brine or water.
ƒ Add CaCl2 powder if brine was not prepared.
ƒ. Thoroughly shear the fluid to develop maximum emulsion stability and viscosity.
ƒ Add cDEEP-TROL required for HPHT fluid loss control and continue shearing.
ƒ If the desired viscosity has not been achieved in the mud plant due to low shear levels even with a
dedicated device, add CONFI-MUL SA which will impart viscosity at low temperature with low shear
in a low solids system.
ƒ Load barite to get the desired density.
ƒ Shear the system to get stable uniform properties.
ƒ Bridging agents should not be mixed in the liquid mud plant (LMP) to avoid shear degradation.
Bridging agents are best added in the field immediately before their use is required.

15
 Section

11c non aqueous drilling fluids

Field Trouble Shooting of the CONFI-DEEP system:

Observation Possible Reasons Recommended Treatment

High PV ƒ Solid build up • Check Shaker screens for holes
ƒ Inefficient or inadequate solid • Use finer screens
removal • Run Centrifuge in correct mode
• Dilute the system with base oil
High YP ƒ Solid build up • For solids as above
ƒ Water contamination • Add base oil to get the correct
ƒ Excess viscosifier OWR and to reduce viscosifier
concentration
High Gels ƒ High LGS • Same as “A”
ƒ High Solids
Non-Flat ƒ Less concentration of cDEEP-MOD • In case Rheological parameters
rheology ƒ Poor emulsification permit add cDEEP-MOD
ƒ High concentration of organophilic • Mix cDEEP-MUL
clays • Dilute SBM with base oil and mix
cDEEP-MOD
Low values of ƒ Reduction in cDEEP-MOD • Mix cDEEP-MOD
LSRV & YP ƒ Reduction in cDEEP-RM • Mix cDEEP-RM – Be careful to
Unstable emulsion ensure Flat rheology is maintained.
Excess of organophilic clay may give
temperature dependent rheology.
• Mix cDEEP-MUL
Low ES ƒ Drop in concentration of • Mix cDEEP-MUL
cDEEP-MUL
High HTHP Fluid ƒ Weak emulsification or less • Add cDEEP-MUL
loss emulsifier in the system • Mix cDEEP-TROL
ƒ Less of Fluid Loss additive • Reduce solids as per “A”
ƒ Less of clay in the system
ƒ Solids build up
Decreasing Oil ƒ Surface water contamination • Check all water sources like taps on
Water ratio ƒ Excessive shale dehydration - surface – check drill floor cleaning
removing water from formation • Bleed in base oil to increase OWR
with concurrent treatment to
maintain parameters
• Observe shale cuttings for being
very brittle & fragile due to excessive
dehydration. Normal dehydration
strengthens shale
• Reduce WPS by dilution and treating
the drilling fluid with proper
additives

Table 10. Supplementary products for EXTRA-VERT systems

16
opta-vert
System Description
OPTA-VERT is an invert emulsion DRILL-IN fluid that has been custom designed to provide minimal
reservoir damage across of a wide range of porosities and permeabilities whilst laying down a filter cake
readily removable on draw down.

The system is custom designed for each individual reservoir and uses a range of high quality
components and design tools to facilitate the design process including the HyPR-SIZER program which
allows the concentration and particle size of the bridging agent to be optimized to ensure solids are
deposited across the pore throat with minimal invasion while sealing off the reservoir with a thin and
resilient filter cake.

OPTA-VERT is recommended for reservoir drill-in applications with the raised potential for problems
such as emulsion blocking associated with water based drilling fluids.
Problems which OPTA-VERT minimises include:

ƒ Wellbore instability caused by hydratable shales above or inter-bedded in the reservoir sands.
ƒ Fluid instability due to high bottom hole temperatures.
ƒ Excessive torque and drag related to high angle and extended reach drilling.

The result is a system that provides strong benefits as a high performance, non-damaging drill-in fluid
optimising production rates across a wide range of completion methods:

ƒ Open hole gravel pack or non gravel pack completions.

ƒ Expandable slotted screen completions.
ƒ Slotted or perforated liner completions.
ƒ Cased hole completions where hole cleaning or minimised fluid invasion is critical.

The system is highly inhibitive and ideally suited to drilling reservoirs with shale interbeds.

The OPTA-VERT system can be used to drill overbalanced by optimising the concentration of the
bridging material to effectively seal new virgin formation as it is exposed by the bit, thus preventing
losses.

Benefits of the OPTA-VERT System include:

ƒ Highly inhibitive ƒ Re-use

ƒ Low filter loss ƒ Can be engineered with environmentally
ƒ Re-use friendly base fluids
ƒ Can be engineered on reservoir specific basis ƒ Simple to use
ƒ Rapid bridging ƒ Fluid properties are tolerant of solids
ƒ Easily removable filter cake ƒ Resistant to contamination
ƒ Filter cake has low lift off pressure ƒ Protection against corrosion
ƒ Filter cake can be back produced through ƒ Low dilution rates
slotted liners ƒ Can be formulated to relatively low
ƒ Acid soluble filter cake densities

17
 Section

11c non aqueous drilling fluids

The advantages of the system must be considered along with the limitations:

ƒ High cost of losses ƒ May require complex clean up procedures

ƒ High initial make up costs ƒ Cost of remediation
ƒ May have environmental restrictions ƒ Re use may lead to build up of drill
solids content
Formulation
An example of an OPTA-VERT formulation and associated properties is shown in Table 11. All formulations
must be engineered specifically for each reservoirs individual characteristics.

Product Function Concentration Concentration

lb/bbl kg/m3
Base Oil LP Base Fluid 0.65 bbl/bbl 0.65 m3/ m3
CONFI-MUL P Primary emulsifier 6-8 11.4
CONFI-MUL S Secondary emulsifier 3-4 8.55 – 11.4
CONFI-GEL Viscosifier 4-6 11.4 – 17.1
calcium chloride Brine phase 15 42.75
drillwater 0.12 bbl/bbl 0.12 m3/ m3
lime Lime 10 28.5
OPTA-CARB Bridging & density 10 – 55 as required 18 – 156 as required

Table 11. Example OPTA-VERT formulation

Property Typical Value Units

Mud Weight 9.1 lb/gal
PV 26 cP
YP 21 lbs/100 ft2
6 RPM 13 dial reading
SWR 85:15
ES 1040 volts
HTHP (@ Bottom Hole Temp °F) <4.0 ml/30 min

Table 12. Typical OPTA-VERT properties

A number of aspects of this formulation need to be highlighted.

ƒ
Note the relatively low concentration of emulsifier. The system is run with little or no excess
emulsifier to minimise emulsion blockage in the formation. However, must be emphasised that the
amount of emulsifier must be sufficient to ensure emulsion stability.
ƒ
Filtration control additives maybe restricted to prevent formation damage. In that case filtration control
is provided by the emulsion and the concentration of bridging material.
ƒ
The concentration, particle size distribution and type of the OPTA-CARB bridging material, will be
project and well specific.

Engineering Guidelines
Ensure that the emulsion remains stable, with low filter loss and no water break through. It is
also imperative that there is sufficient bridging material of the correct size to ensure that the non
damaging nature of the fluid. The drilling process will degrade the bridging material and some of
the material will be removed by the shale shakers. New bridging material should be added to regularly
to the circulating system to maintain the correct particle size distribution.

18
Mixing OPTA-VERT
ƒ Add the required quantity of base fluid to the mixing tank.
ƒ Add the primary emulsifier, CONFI-MUL P, and secondary emulsifier, CONFI-MUL S, as required.
ƒ Add organophilic viscosifier, CONFI-GEL / CONFI-GEL HT, as required.
ƒ Add required amount of water to the above mixture. If brine is to be used, then add brine after the
lime additions.
ƒ Add rheology modifier e.g. CONFI-MOD or CONFI-RM as required.
ƒ Add lime as required.
ƒ Add filtration control additives, CONFI-TROL, CONFI-TROL HT, CONFI-SEAL or CONFI-TROL F, as
required.
ƒ Add calcium chloride powder if brine is not used. If calcium chloride powder is not available, then
mix the calcium chloride flakes into the water and add as a brine.
ƒ Mix above for several hours to ensure a good emulsion is formed.
ƒ If the formulation requires barite add the required amount.
ƒ Add the bridging material e.g. OPTA-CARB as the final product.
ƒ After the bridging material has been added it is advisable that shear in the mixing system is
minimised to prevent the grinding of the bridging material. It is recommended that if logistically
possible the bridging materials are not added to the fluid until it is needed e.g. immediately before
entering the reservoir or after the casing / liner is drilled out.

The shear available on most rigs is rarely sufficient to ensure that the organophilic clays have fully
yielded. Once the fluid is sheared through the bit the rheology profile may increase.

Filter Loss
The HPHT should be run at the maximum expected bottom hole temperature. As there is a minimal
concentration of emulsifiers in the fluid, the HPHT test should be run several times on each shift to
ensure that the fluid remains within the required parameters.

Density
Initial density is provided by the OPTA-CARB in the system. Barite should be added only if the
engineered bridging material is not sufficient to provide the required density.

In order to minimise the amount of solids, alternative weight materials such as HAEMATITE, or for
specialist applications, HYDRO-MAX, may be used. These weight materials will deliver fluids which
have lower plastic viscosities than systems formulated with conventional barite.

Rheology
It must be highlighted that while drilling ahead there will be an increase in rheology as the
organophilic clay yields. This is particularly true when new fresh mud is delivered to or mixed on the rig.
Ensure that this increase in rheology does not become an operational problem, it must be controlled.

The two principal methods of imparting rheology is by the use of the Organophilic clay, CONFI-
GEL / CONFI-GEL HT and or low end rheological modifiers. Optimise the effectiveness of organophilic
clays, with the addition of CONFI-MOD and/or CONFI-RM. The use of these modifiers will provide
a flatter rheology profile minimising the ECD. Note that overuse of rheology modifiers without
sufficient underlying organophilic clay structure can promote barite sag, which is detailed in section 6b
of this handbook, barite sag.

19
 Section

11c non aqueous drilling fluids

Oil Wetting Agents

The use of oil wetting agents, CONFI-WET, and thinners, CONFI-COAT, should be avoided as the
difference between product effectiveness and over treatment can be a very fine balance. The
thinners act on the organophilic agents and destroy their effectiveness. Once a system is over treated
it becomes difficult to re gain the rheology and the danger of sag becomes more pronounced. If a
treatment of oil wetting agents is to be made to the circulating system, it is advisable that the
treatment is pilot tested extensively beforehand to determine the correct treatment level.

Emulsifier
Emulsifier ensures that the invert emulsion is stabilised and aid in filtration control. The measurement
of emulsion stability gives an indication of the condition of the emulsion. While drilling with the
OPTA-VERT system the emulsifier concentration is minimised to prevent formation damage.

Filtration Controllers
The use of filtration controllers may be restricted when using the OPTA –VERT system. However,
depending on fluid loss requirements OPTA-VERT systems may be formulated with the CONFI-
TROL product range or blend of these products.

Water Phase Salinity

Refer to CONFI-DRILL.

Non Standard Rig Site Testing

The primary method of preventing damage is the use of bridging materials. The quantity and quality
(particle size distribution) needs to be monitored. A number of additional testing regimes may be
required. These include

Test Reason Equipment / Test

Pore Plug Test Bridging Efficiency PPA apparatus
Calcium Carbonate Concentration Determine the quantity of Non Standard Test
bridging material
Particle Size Distribution Determine the size of the Malvern Particle Size
particles in the fluid tester

These tests will determine the rate of depletion of bridging material in terms of quantity and quality
which will allow addition of the required bridging material to the system while drilling ahead.

Solids Control Equipment

It must be highlighted that while the primarily purpose of solids control equipment is to remove
drill solids, bridging materials will also be removed negating the non damaging nature of the fluids.
A balance has to be struck between solids removal and controlling the effects of drill solids
contamination by dilution.

Fresh bridging agents are frequently added on a continuous basis to replace material lost through
solids control equipment.

20