Additive for drilling fluid used as a sealing agent to reduce seepage loss and fluid loss in subterranean wellbores

Abstract

An additive for drilling fluid used as a sealing agent to reduce seepage loss and fluid loss in subterranean wellbores. The additive includes ground bituminous coal having a selected particle size distribution and a median particle size added to drilling fluid at a selected rate.

Claims

1. A drilling fluid comprising an additive used as a sealing agent to reduce seepage and fluid loss in subterranean wellbores, which additive comprises: a fluid additive comprising ground bituminous coal having a selected particle size distribution wherein the selected particle size distribution of the ground bituminous coal has approximately 50% of its particles less than 75 microns and a median particle size of 75 microns; and wherein said fluid additive is added to drilling fluid at a rate of between 3 to 6 pounds per barrel.

2. The drilling fluid as set forth in claim 1 wherein the drilling fluid is bentonite based.

3. The drilling fluid, as set forth in claim 1 wherein the drilling fluid is polymer/potassium chloride based.

4. The drilling fluid as set forth in claim 1 wherein the drilling fluid is diesel-oil based.

5. A method to reduce seepage and fluid loss in subterranean wellbores, which method comprises: preparing a fluid additive comprising ground bituminous coal having a selected particle size distribution, wherein the selected particle size distribution of the ground bituminous coal has approximately 50% of its particles less than 75 microns and a median particle size of about 75 microns; adding the fluid additive to a drilling fluid at a rate of between 3 to 6 pounds per barrel; and injecting the drilling fluid with fluid additive downhole in a subterranean wellbore.

6. The method to reduce seepage and fluid loss as set forth in claim 5 wherein the drilling fluid is bentonite based.

7. The method to reduce seepage and fluid loss as set forth in claim 5 wherein the drilling fluid is polymer/potassium chloride based.

8. The method to reduce seepage and fluid loss as set forth in claim 5 wherein the drilling fluid is diesel-oil based.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a graph or chart showing particle size distribution for various drilling fluid additives including additives of the present invention used as a sealing agent to reduce seepage and fluid loss;

(2) FIG. 2 is a graph or chart showing particle size distribution for various additives as a function of the square root of the diameter;

(3) FIG. 3 is a graph or chart of fluid loss in a syringe fluid loss test in a bentonite drilling fluid system;

(4) FIG. 4 is a graph or chart of fluid loss in a bentonite CLS drilling fluid system;

(5) FIG. 5 is a graph or chart showing results of fluid loss in a modified API fluid loss test in a bentonite drilling fluid system;

(6) FIG. 6 is a graph or chart showing results of fluid loss in a modified API fluid loss test in a bentonite CLS drilling fluid system;

(7) FIG. 7 is a graph or chart illustrating results of fluid loss in a syringe fluid loss test for a polymer/potassium chloride drilling fluid system;

(8) FIG. 8 is a graph or chart illustrating results of a syringe penetration test for a polymer/potassium chloride drilling fluid system;

(9) FIG. 9 is a graph or chart illustrating results of fluid loss in a modified API fluid loss test for a polymer/potassium chloride drilling fluid system;

(10) FIG. 10 is a graph or chart showing results of fluid penetration in a syringe fluid loss test in a diesel-oil based drilling fluid;

(11) Fluid 11 is a graph or chart showing results of fluid expelled in a syringe fluid loss test in a diesel-oil based drilling fluid;

(12) FIG. 12 is a graph or chart showing results of fluid expelled in a modified API modified fluid loss test for a diesel-oil based drilling fluid;

(13) FIG. 13 is a table showing the fluid properties of bentonite drilling fluids;

(14) FIG. 14 is a table showing the fluid properties of polymer/potassium chloride drilling fluids; and

(15) FIG. 15 is a table showing fluid properties of diesel-oil based systems.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(16) The embodiments discussed herein are merely illustrative of specific manners in which to make and use the invention and are not to be interpreted as limiting the scope of the instant invention.

(17) While the invention has been described with a certain degree of particularity, it is to be noted that many modifications may be made in the details of the invention's construction and the arrangement of its components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification.

(18) As set forth in this description and in the drawings, the following codes are employed to refer to additives of the present invention having selected particle size as follows:

(19) Code Table

(20) CGcement grade additive

(21) MG Coarsemud grade coarse grind additive

(22) MG Mediummud grade medium grind additive

(23) MG Finemud grade fine grind additive

(24) In laboratory tests conducted for sealing which will be described herein, 20/40 mesh sand was used for one test and 30/40 mesh sand for the other test. In these mesh sizes; the largest particles will be about 850 and 600, respectively. The largest pore sizes for these sands can be calculated to be approximately 470 and 350, respectively. Based on a measured permeability of 119 Darcies (a measure of permeability), the median pore size for the 20/40 sand can be calculated to be around 345.

(25) FIG. 1 is a chart plot of particle size distribution for several different additives including those of the present invention. Those to the right in the chart plot have larger sized particles than those to the left. The particle size nominal diameter is shown on the X axis while the cumulative % less than the nominal diameter is shown on the Y axis.

(26) Thus, the CaCO3 fine additive (see Gaurina-Medimurec, N., Laboratory Evaluation of Calcium Carbonate Particle Size Selection for Drill-In Fluids, Rudarsko-geolosko-nafinizbornik (2002), Vol. 14, pages 47-53) is far to the left while the CG additive is far to the right. The uintaite and natural asphalts are all to the left of the MG grinds used in the tests, meaning that their particle sizes are generally significantly smaller than the other grinds. The uintaites and natural asphalts are similar in size distribution to each other. The CalCarb 80 is more nearly equal to MG Fine.

(27) One model for particle sizing is known as Abrams' Median Particle-Size Rule. If we use Abrams' sizing rule, the median particle size for something expected to seal 20/40 sand should be of 350 or about 118. The median particle sizes for the MG grinds (75, 100, and 170) makes them nearer to the ideal size than any of the uintaites or natural asphalt additive.

(28) The D.sub.90's for MG Fine, Medium, and Coarse are approximately 250, 350, and 600. Thus, the D.sub.90 for MG Fine and MG Medium are equal to or less than the largest pore size for the 20/40 and 30/40 sand (470 and 350) and therefore satisfy Hands' rule.

(29) The uintaites and natural asphalts fluids tested all have a much smaller particle size distribution than the MG grinds while the CG grind has much larger particles. The uintaite and natural asphalt median particle sizes will be a good bit less than ideal in our tests according to Abrams' sizing rule. The median particle size for CG can be estimated to be around 550 or much larger than Abrams' rule would recommend. Neither the uintaites, the natural asphalts nor CG would be expected to seal as well against the two sands as the MG grinds. This was borne out in the laboratory tests where the proprietary MG grinds of the present invention sealed as well or better than treated uintaite or untreated natural asphalt. CG did not seal at all. However, the uintaites and natural asphalts would be expected to seal formations with smaller pore sizes. Likewise, CG should seal formations with larger pore sizes and therefore might be suitable as a lost circulation material.

(30) Another method used to evaluate the proper size distribution for particles to achieve sealing is the ideal packing theory (IPT). This theory says that ideal packing occurs when the percent of cumulative volume vs. the D.sup.1/2 forms a straight-line relationship, where D.sup.1/2 is the square root of the particle diameter. See Dick et al., ibid. and Kaeuffer, M., Determination de L'Optiumum de Remplissage Granulometrique et Quelques Proprietes S'y Rattachant, presented at Congres Internationa de l'A.F.T.P.V., Rouen, October 1973. FIG. 2 shows a plot of particle size distribution of some of the additives as a function of the square root of the particle size. The square root of the diameter is shown on the X axis. The cumulative % less than the diameter is shown on the Y axis. Again, additives with larger particle sizes are to the right and those with smaller particle size distributions are to the left.

(31) FIG. 2 illustrates a graph or chart showing particle size distribution for various additives including those of the present invention, as a function of the square root of the diameter. FIG. 2 also includes lines for the calculated ideal maximum size particle for 20/40 sand (850, D.sup.1/2=29) and 30/40 sand (600, D.sup.1/2=24). These are the two straight lines starting at the origin and end at 29 and 24, respectfully. According to the IPT, ideally sized materials for sealing the sands would have a straight line section coinciding with these lines. As seen in FIG. 2, none of the materials fall exactly on the sand lines, but the MG grinds are closer than the additive.

(32) Based on the particle size distribution in FIG. 2, the uintaites would be expected to be ideal for sealing porous rock with a maximum particle size around 125 (D.sup.1/2=11). Sand this size would pass through a 120 mesh screen. Likewise, MG Fine should be ideal for sealing formations with a maximum particle size around 250 (pass through a 60 mesh screen, D.sup.1/2=16). Theoretically, the MG Coarse comes closest to being ideal for sealing the two sands used in the tests. However, the total solid particle size distribution will be impacted by the presence of bentonite or drill solids.

(33) As mentioned previously, calcium carbonate can be ground to a variety of sizes. For example, Global Drilling's Glo Carb comes in extra fine, fine, medium, and coarse grades with median particle sizes of 2-5, 10-14, 135-165, and 550-650, respectively. The fine material is used as a weighting agent, whereas the coarse and medium grades are used for bridging and seepage control. The MG grinds median particle sizes (75, 100, and 170) are similar to Glo Carb medium while CG would be more similar to Glo Carb coarse.

(34) Experimental Results:

(35) Bentonite Drilling Fluids:

(36) A series of tests were conducted using various MG grind in a simple 16.9 ppb bentonite drilling fluid and in a 22.5 ppb bentonite chrome lignosulfonate additives. These results were compared to similar tests of treated uintaite and treated Columbian natural asphalt. The results are summarized in a table shown in FIG. 13. The additives were added to the drilling fluids at a rate shown in the column Additive, ppb.

(37) 1. Rheology: Standard viscosity measurements were taken after aging overnight at room temperature. The MG grinds do not appear to impact the properties of the 16.9 ppb fluid. Plastic viscosity, yield point and gel strengths were slightly higher for the MG Fine in the 22.5 ppb CLS than the base fluid.

(38) 2. Fluid Loss: Standard API (American Petroleum Institute) fluid loss tests (API-RP-13B) were conducted on a number of the drilling fluids. However, previous experience has shown that the standard API test does not adequately distinguish between fluids when being tested for sealing during drilling operations. Therefore, modified fluid loss tests as described in detail below were also conducted.

(39) 3. Syringe Test: FIG. 3 is a chart or graph of fluid loss in a syringe fluid loss test for various additives. In this test, 20/40 sand was placed in a 50 mL syringe. The test fluid was introduced at the top and pressure is applied to see how far the fluid travels in the sand and whether fluid comes through at the bottom. If fluid is expelled, the penetration is listed as 24 mL and the amount of fluid is measured. A detailed description of the test is given below.

(40) In the 16.9 ppb bentonite drilling fluid, all the treated fluids exhibited complete penetration but differed as to the amount of fluid expelled. As shown in FIG. 3, the base fluid was essentially all expelled. The MG Fine grind gave excellent performance with no fluid expelled. One of the two treated uintaites tested also had no fluid expelled. As expected, the CG additive did not seal against the 20/40 sand.

(41) In the 22.5 ppb bentonite CLS fluid, the MG Fine, the treated Columbian natural asphalt, and treated uintaite all sealed, although the treated uintaite slightly less well than the other two products as seen in the chart or graph in FIG. 4.

(42) 4. Modified API Fluid Loss: FIGS. 5 and 6 are graphs or charts illustrating results of fluid loss in a modified API fluid loss test for bentonite systems. In the modified API fluid loss test, the fluid loss is measured through a 1-inch bed of 30/40 sand instead of through filter paper. A detailed description is given below.

(43) For the 16.9 ppb bentonite drilling fluid, the various MG grinds exhibited comparable performance to the Columbian natural asphalt and the treated uintaite samples. Again, the particle size range of the CG additive was too large for effective sealing for this sand size.

(44) For the 22.5 ppb bentonite CLS fluid, the MG Fine additive gave the best performance with only 24.7 mL expelled compared to 39.5 mL treated Columbian natural asphalt, 61.5 mL for treated uintaite, and 154 mL for the base fluid.

(45) X-C Polymer Systems:

(46) Tests similar to those described above were performed on X-C polymer mud systems containing various MG grind additives and treated uintaite. The base drilling fluids contained 1.0 ppb X-C polymer, 5% KCl (potassium chloride), and 30 ppb RevDust to simulate drill solids. RevDust was added because previous work has shown that X-C polymer systems containing no drill solids do not seal well even with high product concentrations. RevDust is a clay material used as a substitute for drill solids encountered in actual operations. The results are shown in the table in FIG. 14.

(47) 1. Rheology: The X-C polymer drilling fluids showed no significant differences in plastic viscosity, yield point, or gel strengths with addition of any of the products.

(48) 2. Fluid Loss: The standard API fluid loss values of the X-C systems were essentially identical for the three products.

(49) 3. Syringe Test: FIG. 7 is a graph or chart illustrating results of fluid loss in a syringe sand test for a polymer/potassium chloride system. The syringe test was performed on the fluids after aging overnight at room temperature. FIG. 7 shows the fluid expelled and FIG. 8 shows the syringe penetration. The base drilling fluid showed no sealing with complete penetration of the fluid and essentially all of the fluid being expelled.

(50) As shown in the table in FIG. 8, the MG Coarse, the MG Medium, and the MG Fine additives sealed with little or no fluid expelled. The treated Columbian natural asphalt gave comparable results. The two treated uintaite samples gave different results. The first sample gave no sealing with all fluid being expelled. The second sample sealed with no fluid expelled and 15 mL of penetration.

(51) 4. Modified API Fluid Loss: FIG. 9 is a graph or chart illustrating the results of fluid loss in a modified API fluid loss test. The modified API fluid loss test in which the normal filter paper is replaced by a sand layer was conducted on the fluids. The untreated fluid showed essentially no sealing behavior. As shown in FIG. 9, the MG Coarse, MG Medium, and MG Fine were comparable in performance to the treated Columbian asphalt and performed considerably better than either sample of treated uintaite.

(52) Oil-Based Drilling Fluid:

(53) The MG Fine additive, untreated uintaite, and untreated Columbian natural asphalt were tested in an unweighted, 7.7 ppg diesel oil-based generic mud. The results are shown in the table in FIG. 15.

(54) 1. Rheology: The diesel fluids showed no significant differences in plastic viscosity, yield point, or gel strengths with addition of any of the products.

(55) 2. Fluid Loss: The standard API fluid loss values of the fluids were essentially identical for the tested products.

(56) 3. Syringe Test: FIGS. 10 and 11 are charts or graphs of fluid loss tests for various additives. At 2 ppb product, the MG Fine additive sealed better than either untreated uintaite or untreated Columbian natural asphalt. At 4 ppb, both the MG Fine additive and the untreated uintaite sealed with no fluid expelled. The untreated uintaite penetrated slightly less than the MG Fine additive. Results are shown in FIGS. 10 and 11. FIG. 10 illustrates the amount of fluid expelled and FIG. 11 gives the amount of fluid penetration.

(57) 4. Modified API fluid loss: As in the syringe test, MG Fine at 2 ppb sealed better than either untreated uintaite or untreated Columbian natural asphalt. For the latter two products, essentially all the fluid was expelled within the first 30 seconds. At 4 ppb, MG Fine allowed significantly less fluid to be expelled than the untreated uintaite. These results are shown in FIG. 12.

(58) Experimental Procedures:

(59) Bentonite Drilling Fluids:

(60) All of the drilling fluids contained water and bentonite. The base bentonite fluid was mixed on a Hamilton Beach multimixer for 5 minutes, scraped down and mixed an additional 10 minutes. The fluid was combined with additional samples and aged overnight. The base fluid was mixed with a paint mixer after aging. The additives were then added to individual lab barrels while mixing on the multimixer. The fluids were mixed for 5 minutes, scraped down and mixed an additional 10 minutes. The pH was adjusted to about 10 using 1 N KOH. The fluids were aged overnight at room temperature and rheologies measured after mixing 5 minutes and adjusting pH again. Rheologies were measured on an Ofite Model 900 rheometer at room temperature.

(61) X-C Polymer/5% KCl Drilling Fluids:

(62) To make the base fluid, 350 g of 5% KCl in distilled water was added to a mixer cup. 1.0 gram X-C Polymer was slowly added to the cup while mixing on the multimixer, and then 30 grams of RevDust added with mixing. After 20 minutes on the multimixer, the appropriate amount of the product of interest was added slowly and mixed for 10 minutes. The pH was adjusted to about 10 with 1 N KOH solution. The samples were aged overnight. After aging, each sample is mixed 5 minutes and the pH readjusted before the rheological properties are measured and the fluid loss tests performed.

(63) Oil-Based Drilling Fluid:

(64) The diesel oil-based drilling fluid was a generic unweighted fluid provided by Intertek Westport Technology Center, 6700 Portwest Drive, Houston Tex. 77024. After product addition, the samples were aged overnight at room temperature.

(65) Syringe Test:

(66) Place 45 grams of 20/40 sand in a 60 mL plastic syringe. Tap the syringe with the syringe top, and then tap the tip on the lab bench top to settle the sand which will come to about the 25 mL mark on the syringe barrel. Pour the fluid to be tested gently into the syringe so as not to disturb the surface of the sand fill to about the 53 mL mark. Insert the plunger. Hold the syringe and a 25 mL graduated cylinder with both hands so the tip of the syringe is in the neck of the graduated cylinder. Place the top of the plunger under a sturdy table top and push the barrel up with both hands with as much force as possible. When liquid stops flowing from the tip, release the pressure and measure the fluid collected in the graduated cylinder. If no liquid passes through the sand column, note the distance (in mL marks) from the top of the sand column to the level to which the liquid penetrated.

(67) Modified API Test Using a Sand Bed:

(68) In the standard API fluid loss cell, pour 200 grams of 30/40 sand onto the screen at the bottom of the cell. Tap the side of the cell with a rubber mallet with some vigor to settle the sand. Ensure that the surface of the sand is level but do not touch the surface. Pour 200 mL of the fluid to be tested slowly and gently through a fine metal screen suspended about 0.5 cm above the sand surfacedo not let the screen touch the surface while pouring the liquid. (The screen is cut to fit inside the API cell with three fine wires attached to form a handle by which the screen can be held above the sand and then gently withdrawn from the cell.) Do not let the screen touch the surface while pouring the liquid. The goal is to disturb the sand surface a minimum amount. Assemble the cell as normal. Place a 250 mL beaker below the cell to catch effluent. Slowly open the valve to the cell to bring the pressure in the cell to 100 psi. When liquid begins to exit the cell or the valve is fully open, start the 30 second timer. If the tested material forms a seal, only part of the liquid contents will be expelled in the 30 second period. Change the beaker for another one and start the 30 minute timer. Measure the volumes for both parts of the tests as normal.

(69) In summary, the present invention directed to an additive of bituminous coal having a selected particle size distribution and a median particle size added to drilling fluid at a selected rate has proved to be an effective sealing agent to reduce seepage loss and fluid loss in subterranean wellbores.

(70) In view of the foregoing, it is proposed to employ an additive for drilling fluid for mud grade coarse grind applications of ground bituminous coal having a selected particle size distribution of approximately 25% of its particles less than 75 microns and a median particle size of around 170 microns.

(71) It is further proposed to employ a mud grade medium grind additive wherein the selected particle size distribution of the bituminous coal has approximately 35% of its particles less than 75 microns and a median particle size of about 100 microns.

(72) It is further proposed to employ a mud grade fine grind additive wherein the selected particle size distribution of the ground bituminous coal has approximately 50% of its particles less than 75 microns and a median particle size of around 75 microns.

(73) The present invention will maximize reduction in seepage loss and fluid loss while minimizing the additives to the drilling fluid.

(74) Whereas, the present invention has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention.